Rejuvenate the Manufacturing Force with IIoT Practical lessons learned through the MQM Testbed

Transcription

1 Rejuvenate the Manufacturing Force with IIoT Practical lessons learned through the MQM Testbed Mitch Tseng, Ph.D. Huawei Technologies /Tseng InfoServ, LLC March 29-31, 2017 IIC MQM Testbed Partners:

2 Abstract -Rejuvenate the Manufacturing Force with IIoT China has been the World s Factory, especially for manufacturing labor-intensive products, for more than two decades. In recent years, when the world is moving towards Smart Manufacturing, the Chinese industry has been feeling the pinch from facing the enormous challenges of the number and the diversity of factories need to be upgraded. Although superseding the old ones with modern factories through the green-field approach seems to be straightforward, the excessive capital investment for demolishing the old factories and replacing them with contemporary ones has become formidable. Furthermore, workers need to be temporarily furloughed during the period of constructing the new factories can cause severe social challenges as well. As a result, in addition to simply building new modern factories, how to effectively retrofit the existing factories with new sensing, control and intelligent platform to help improve decision-making technologies developed through supporting the Industrial Internet of Thing (IIoT), will be crucial. Manufacturing Quality Management (MQM) Testbed in Industrial Internet Consortium (IIC) is an initiative supported by Huawei, Haier, China Telecom, and CAICT (China Academy of Information and Communications Technology) with a goal to deal with the aforementioned matter. The objective of the testbed is to create a repeatable process so as to renovate and retrofit the legacy manufacturing facilities with quality improvement as a cohesive objective measure. By managing the quality measures all through the production line and using it as the key factor to demonstrate the effectiveness of the improvement while modernizing the existing factory, the team adopted IIC s reference architecture and constructed the testbed with advanced data collection, analysis, and process management capability. The MQM Testbed is targeted to be completed in late There have been many challenges, including unexpected limitations eventually forced the team to change the initial design. These experiences, although painful, are good lessons learned and will be beneficial to parties interested in engaging in similar activities. Moreover, MQM is an essential building block for Intelligent Manufacturing, which is the core of Made in China 2025 initiative. The initiative was kicked-off by the Chinese State Department on May 8th, 2015 with an aim to transform the conventional production systems into Intelligent Manufacturing systems by leveraging the technology development of ICT and IoT. 2

3 Industrial Internet Consortium - IIC Mission The IIC is a global, member supported organization that promotes the accelerated growth of the Industrial Internet of Things by coordinating ecosystem initiativesto securely connect, control and integrate assets and systems of assets with people, processes and data using common architectures, interoperability and open standards to deliver transformational business and societal outcomes across industries and public infrastructure. Launched in March 2014 by five founding members: 270+ Member Organizations Spanning 30+ Countries The IIC is an open, neutral sandbox where industry, academia and government meet to collaborate, innovate and enable. 3

4 Organization Structure of IIC Legal Working Group (21) (6) 4

5 IIC Testbeds! IIC has by far the industry s most comprehensive testbed program (26 approved with several in the queue) Key goals Ensure practical guidance Make impact Span the industry MQM Testbed

6 Testbed Provides Tangible Values to IIC Members Encourage teaming and ecosystem development Help member companies correctly apply IIC guidance Provide market visibility Lend market credibility to member companies by implying that the IIC acknowledges leadership in specific application areas Provide opportunity to secure proof points and partner/customer exposure for nascent technologies Increase the likelihood of securing government or company funding Testbed Value Members IIC Industry 6

7 MQM Testbed: Vision, Goals, Impact, and Benefits Objective: Develop a repeatable process to renovate and retrofit the legacy manufacturing facilities Using Quality as Measure; Based on IIC Reference Architecture. Policy Compliance Society Harmony Public Funding MQM Testbed Brown vs. Green Values Business Industrial Tangible Benefits Foster Business Success Smarter and Greener 7

8 What is Manufacturing Quality Management (MQM MQM)? Manufacturing Quality Management (MQM) is an essential building block for Intelligent Manufacturing, which is the core of Made in China 2025 [Note]. The proposed MQM system is part of the 94 State approved projectsto address: Economically-Lowering CAPEX for factory renovation Socially- Minimizing impacts to existing workers in the process. A key objective is to create a repeatable process to renovate and retrofit the legacy manufacturing facilities With quality improvement as an cohesive objective measure in the core process; With advanced data collection, analysis, and process management capability. [Note] The Chinese State Department kicked-off the Made in China 2025 initiative on May 8, 2015, with an aim to transform the conventional production systems into Intelligent Manufacturing systems by leveraging the technology development of ICT and IoT. 8

9 Overview: Manufacturing Quality Management Testbed Collaborators: Huawei, Haier, China Telecom, and CAICT Market Segment: Manufacturing quality management in home appliance industry and can be extended to other manufacturing-oriented sector. Goal: To establish a repeatable process and means to: Analyze and remodel the tooling for a manufacturing facility; Improve product quality through modern sensing and process control. 9

10 MQM Testbed Focus: Brownfield Approach to Renovating Manufacturing The MQM testbed is focused on identifying a repeatable quality management process to help renovate and modernize existing manufacturing facilitiesto meet the challenges of high quality standards in the future. Furthermore, the MQM testbed will: retrofit the existing manufacturing facilities with advanced technologies, leverage the IoT and sensory network technologies for effective data acquisition, employ cognitive data analysis to adaptively upgrade the manufacturing process, include energy efficiencyand environment control into manufacturing process. 10

11 Targeted Commercial Benefits Backward Production Facilities Replacement New IIoT Technologies Customization Service Production Efficiency 5% Step1 Production Efficiency 10% Step2 Production Efficiency 15% Step3 Manpower 55%, Cost 27%, Productivity 15%, Customization Lowering the CAPEX and OPEX; Increasing the Production Efficiency. 11

12 The Initial Usage Scenario Decrease Defect Rate of Automatic Welding Current yield for automatic welding of air-conditioning condensers is far from satisfaction; Control parameters are expected to be recorded and transferred to manufacturing platform for analysis; however, the current installment can not adequately address the issue; With appropriate data analysis and process modification, the optimal combination of the settings of the tooling can be determined; and, The process can be adjusted in real-time. 12

13 Challenges in the Current Environment Sensors (some for Environmental Control) Machines (no built-in Sensing capability) Quality Monitors (by visual Inspection) Factory and Production Lines Switch Router IoT Gateway Data transmission is not reliable. Network Platform Data needed are not always available; Data Integrity is not guaranteed. Some Statistical Data Processing but results are not useful. Data Storage cannot handle the amount of data No means to handle lossy or faulty data DAS NAS SAN Object Production Management Fault Prediction Cannot be done Focus on only Single point Solution No in-depth Analysis for Quality Management User/ Manager Must be on-site No Remote Management Some data network deployed in a lossy environment 13

14 MQM Testbed to Meet the Challenges Using the IIRA The testbed utilizes the IIRA s Three-tier architecture pattern Sensors (e.g. Thermal Imaging Sensors) Reference Architecture: Machines (e.g. Welding Machines) Quality Monitors 14

15 Platform Tier Brain-like Cognitive Platform cognitive analytics and soft computing novel learning algorithms and control protocols APIs Data Processing Platform computing framework: computing task scheduling and resource management high throughput messaging path Intelligent Storage Platform Data Aware Engine Content Analytics Unified Storage Engine Image Content Analysis Image Audio Document Unified Storage Interface Content Analytics AudioContent Analysis Document Content Analysis hardware hardware hardware hot warm cold 15

16 MQM Testbed Security Considerations Threat Model Reviewed with the Security Working Group. Edge Tier Platform Tier Enterprise Tier Sensors (e.g. Thermal Imaging Sensors) Machines (e.g. Welding Machines) Quality Monitors 1 2 Firewall Switch 3 Router IoT Gateway 4 Network Analytical Platform (Cognitive Analytics plus Third-Party Solutions) 5 Data Processing Platform Intelligent Storage Platform (With In-House or Third-Party Solutions) DAS NAS SAN Object 6 Fault Prediction 7 Quality Management 8 https User/ Manager Sensory Network This will be considered in more detail during the Testbed Design Phase. 16

17 Deployment & Funding DEPLOYMENT The deployment and operation of this testbed will be in China, initially. The physical components will be installed on premise in the manufacturing or maintenance sites. Meanwhile, software can be deployed on premise or through the cloud, depending on the requirements. Access control and management are limited to the participants. FUNDING Funding for the testbed will be from the participating companies. 17

18 Testbed Innovation and Experimentation From 36,000 feet, every Testbed looks alike! Sensory Network, Analytic, Management, etc. The devil is in the details! You won t even notice it until it hits you! Lesson/Challenges learned from Current Phase: 1. Focusing on Analytic Engine Proven to be effective (help improve the yield rate) Under usage of the Cognitive Computing Platform 2. Retrofitting the sensing module Challenges of integrating the sensors Work with the vendors of the existing sensing units 3. Accommodating the existing operations The old process may not fit for the future. Need new thinking in business planning. Where it might fail Challenges: Technical, Business, Field, Evolution 18

19 Testbed Outputs and Results MQM Testbed Results and Key Findings: 1. Phase 1 (H1/2016): Requirements Completed. Discovered that sensing module for welding section not practical. 2. Phase 2 (H2/2016): Refocus on Noise Detection. Testbed Design Completed. 3. Phase 3 (H1/2017): Integrating the Noise Detection Modules (On going ) 4. Phase 4 (H2/2017): Testbed Deployment and Validation (On going ) Lesson Learned: When dealing with a field issue, listen carefully to establish the common ground first. Recognize the IT/OT knowledge gap! A WeChat Group for key personnel was established to exchange information. Do not underestimate the difference between the field deployment and in the Lab. You won t even notice it until it hits you! Human Factor is much harder than Tech. MQM 2.0: In addition to retrofitting the current processes, we will look into transition the old process into the new ones ( overhaul to rebuild the manufacturing process). Open up the opportunities for further collaborations with IIC Members. 19

20 Importance to IIC and Ecosystem Contributions When the Rubber Hits the Road Facilitate collaboration among IIC Members Real Challenge (not proto type, Deal with real world Scenarios), Real Customer (Not If I build it, they will come! ), High risk, but high learning/gain Calling all hands (Collaboration for the MQM Testbed) As promised, the team is ready to work with other IIC Members to jointly exploit the Testbed: Partners need Edge Computing Platform (IoTGateway, Agile Controller and Cognitive Computing). The cognitive computing could deal with text, voice, picture and video input sources. Field System Integration and Operation Refinement (OT Specialists) MQM Business Planning and Event Processing Platform. Specialized sensors and Sensory Subsystems. Collaboration among ALL IIC Members! 20

21 Thank You 21