Stride towards Made in China Smart Manufacturing through Industrial IoT (IIoT)

Transcription

1 Stride towards Made in China Smart Manufacturing through Industrial IoT (IIoT) International Mold Conference, Bucheon City, Korea Mitch Tseng, Ph.D. Huawei Technologies /Tseng InfoServ, LLC November 3, 2017 IIC MQM Testbed Partners:

2 Abstract - Stride towards Made in China 2025 China has been the World's Factory for more than two decades. While attempting to upgrade its manufacturing basis to meet the objective of "Made in China 2025", a systematic means is needed to not only effectively transforming the old manufacturing facilities into modern ones, but also minimizing the impact to the society. A "Manufacturing Quality Management (MQM) Testbed" developed in Industrial Internet Consortium is an initiative supported by Huawei, Haier, China Academy of Information and Communications Technology (CAICT) and China Telecom with an objective to meet the challenge. The key of the MQM Testbed is to focusing on the quality measurement and establish a repeatable process to renovate and retrofit the legacy manufacturing facilities to meet the contemporary standards by adding sensory network as well as deep learning based analytic engine. The work on MQM Testbed is ongoing with demonstrable improvements and the Testbed is targeted to be completed by the end of Moreover, MQM Testbed has provided a solid building block for "Intelligent Manufacturing", which is a core of "Made in China 2025". An association, Alliance of Industrial Internet (AII), is also mirroring the work in IIC to focus on developing Smart Factories. 2

3 Overview 1. Smart Manufacturing a National Strategy 2. Introduction of Industrial Internet Consortium (IIC) 3. Moving Forward with IIC Testbeds MQM Testbed 4. Activities of Alliance of Industrial Internet (AII) in China 5. Be Successful by Working Together 3

4 Modernize Manufacturing has become a National Strategy Inspired by the movement of Industry 4.0, many countries such as Germany, US, Korea and China, have started similar activities to facing this trend. Modernize the manufacturing process by leveraging the industrial development: Robotics Manufacturing Process Sensors and Data Gathering 2049 年高阶智能 Cloud and Edge Computing 2035 年智能化中国制造 2025 德国工业 4.0 Machine Learning/Deep Learning 2025 年两化融合 Connected Factories 1980 年自动化 Industrial IoT 工厂发展趋势 智慧制造 : 振兴制造业上升为国家战略, 从自动化向智能化转型 美国先进制造 2.0 韩国制造创新 3.0 4

5 Made in China 2025 Inspired by Industry 4.0 an attempt to modernize manufacturing capability and productivity through intelligent manufacturing by applying information technology to connect the elements of the automation processes. An initiative to comprehensively upgrade Chinese industry by leveraging the development of Internet of Things (IoT). 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. Focus on 10 Key Sectors and, initially, with 94 State Approved Projects. 5

6 Challenges in today s Manufacturing Process 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 6

7 Manufacturing Quality Management (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 projects to 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. 7

8 Stride towards Intelligent Manufacturing Policy National Level Direction Setting Focused Industrial Sectors Goals Economical, Technical, Societal, and Environmental Planning Project Solicitation and Approval Linkage among all projects including timeline alignment Practice Identify Resources Domestic and International Information Platform for International Participation Experimentation and Process Evolution 8

9 Industrial Internet Consortium - IIC Vision The Industrial Internet Consortium (IIC) is the world s leading organization transforming business and society by accelerating the Internet of Things (IIoT). Mission Our mission is to deliver a trustworthy Industrial Internet of Things (IIoT) in which the world s systems and devices are securely connected and controlled to deliver transformational outcomes. 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. 9

10 Organization Structure of IIC Legal Working Group (22) (6) 10

11 Moving Forward with IIC Testbeds! IIC has by far the industry s most comprehensive testbed program (28 approved with several in the queue) Key goals Ensure practical guidance Make impact Span the industry MQM Testbed

12 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 12

13 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 13

14 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. 14

15 MQM Testbed Focus: Brownfield Approach to Smart Manufacturing The MQM testbed is focused on identifying a repeatable quality management process to help renovate and modernize existing manufacturing facilities to 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 efficiency and environment control into manufacturing process. 15

16 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. 16

17 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. 17

18 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 18

19 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 Audio Content Analysis Document Content Analysis hardware hardware hardware hot warm cold 19

20 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. 20

21 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 21

22 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. 22

23 AII Activities: Enterprise Explorations Nowadays, Chinese enterprises ACTIVELY carry out the exploration & practice on industrial internet. Based on the massive investigations, FOUR categories of industrial internet models are summaries: Intelligent Manufacturing (inside of factory) Collaborative Manufacturing (factory to factory) Personalized Customization (customer to factory) Service-Oriented Manufacturing (product to factory)

24 Field OT layer Workshop IT layer Enterprise Exploration-- Intelligent Manufacturing Deploy built-in systems and new ERP & PLM Big data analysis Cloud-based application External network networks on legacy manufacturing systems to Management network SCADA MES Data gateway Gateway Industry data platform External gateway implement data collection & integration, big data analysis & optimization, as well as smart production & management Control network HMI PLC Example: Haier Internet factory Interconnection of device layer, production zone interconnection New sensor layer, headquarter interconnection Monitoring device Actuator Sensor layer, internet layer Develop factory information cloud New network platform (COSMO) 24

25 Inside the enterprise Outside the enterprise Enterprise Exploration-- Collaborative Manufacturing Use the inter-enterprise network or industrial cloud platform to implement Collaborative factory Collaborative factory Collaborative factory Collaborative factory Collaborative factory Collaborative factory new manufacturing modes such as collaborative design, crowdsourcing design, and supply chain coordination Industrial cloud platform Internet Example: CAXA industrial cloud service platform Gateway Data gateway CAX PDM ERP SCM MES External gateway Management network Supply with cloud design tools, cloud manufacturing applications, cloud coordination platform, cloud storage, etc. In one children s electric vehicle project, products are brought to market in 3 months by collaboration, while 1 year is required at least using legacy manufacturing mode, including design, experiment, supplier adjustment, product 25

26 OT layer IT layer Outside the enterprise Enterprise Exploration-- Personalized Customization User Transforming customized requirements into production orders Production device Customized production platform Production device User Data gateway ERP MES SCADA Production device User Order Internet SCM Production material Production device Sending material requirements to providers based on production orders Provider Reconstruct the Internet platform and enterprise management system to transform customized requirements into production orders and implement on-demand production Example: Homekoo Furniture Customized 300,000 new customs information per year. Based on big data, support market prediction, partner selection, product optimization, etc. Have modularization and flexible production line Revenue keeps rising in 60%, lumber utilization rate is 93%, while the whole industry is 12% and 85% respectively on average 26

27 IT layer Outside the enterprise Enterprise Exploration-- Service-Oriented Manufacturing Add smart modules on products Product Environment to implement product Smart module Monitoring module networking and operation data collection Provide smart services such as Data integration analysis software Smart module Smart module product predictive maintenance Product Product using big data analysis Data analysis Data integration Data gateway Data switch External gateway Example: SANY remote services More than 230 thousand equipment PLM are connected to internet CAX CAE CAPP ERP SCM IT network More 5000 parameters are collected By O&M system, customer portal GCP and CRM system, rapid response could be given. 27

28 Be Successful by Working Together - IIC can help! 1. Refine YOUR Technologies or Processes. Technical discussions with IT and OT experts through TG activities. Contributing and Adopt the IIC reference documents. 2. Establish International Partnership. True collaboration through Testbed activities. Gathering the first-hand and most-needed information. 3. Train the talents to explore global market. Through Presentation and Interaction opportunities Through Coaching by experts By Facing the real world s issues through IIC activities. mitch@t-infoserv.com 28

29 Thank You 29