Digitalizacija proizvodnje in prehod v pametne tovarne
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1 Digitalizacija proizvodnje in prehod v pametne tovarne 10. posvet dolenjskih in belokranjskih informatikov Vanja Tomažič
2 Metronik je vodilno regijsko podjetje na področju proizvodne informatike in avtomatike Podjetje Ustanovljeno 1990 Pisarne v 4 državah (SLO, HR, SRB, BG) Letni promet 12 mio Od leta 1993 Partnerji Premier Solution Partner od leta zaposlenih Široko področje kompetenc in izkušenj Projektna skupina 70 inženirjev Zaposleni Farmacevtska proizvodnja Druge proizvodnje Infrastruktura in energetika Avtomatizacija zgradb Stranke
3 Prehod od Industrije 1.0 do Industrije 4.0 Četrta industrijska revolucija Degree of complexity First Industrial Revolution based on the introduction of mechanical production equipment driven by water and steam power First Mechanical loom, 1784 Second Industrial Revolution based on mass production achieved by division of labor and the use of electrical energy First conveyor belt, Cincinnati slaughterhouse, 1870 Mass Prod. Ford T, 1908 Third Industrial Revolution based on the use of electronics and IT to further automate production First programmable logic controller (PLC) Modicon 084, 1969 Fourth Industrial Revolution based on the use of cyber-physical systems Today Time Source: DFKI (2011)
4 Cyber Physical Systems Definicija Cyber Physical Systems (CPS) so pametni povezani sistemi z vgrajenimi senzorji, procesorji in aktuatorji, ki čutijo (se zavedajo okolja) in se odzivajo v fizičnem okolju. Source: Federal Networking and Information Technology Research and Development (NITRD) Program - Dec. 11, 2012
5 Sile, ki oblikujejo industrijski internet Internet stvari 2 Inteligentne 3 Množica naprave podatkov 1 4 Analitika Živa mreža naprav, podatkov in ljudi Naraščajoča inteligenca vgrajene programske opreme Transformacija velike količine podatkov in informacij v inteligenco Vpogled v podatke in izboljšanje performanc
6 Možne smeri iniciative Industry 4.0. za tovarne Proizvodni fokus - INTERNO Centraliziran zajem procesnih podatkov iz proizvodnih naprav/linij Inteligentna korelacija med surovimi podatki in organizacijskim modelom Interakcija med napravami, izdelki v proizvodnji in ljudmi v realnem času Analitika, simulacija in predikcija Fokus na izdelke - EKSTERNO Vsak izdelek je opremljen z IoT logiko Optimizacija vzdrževanja Rešitve v oblakih za stranke Napredne storitve za stranke
7 Možne smeri iniciative Industry 4.0. za tovarne Proizvodni fokus INTERNO Varen zajem podatkov iz proizvodnje, kakovosti, logistike, skladišč - IoT Optimizacija procesov in operativna odličnost Energetska učinkovitost Ravnanje z odpadki Optimizacija logistike Planiranje proizvodnje v realnem času Analitika procesa in procesnih parametrov Predikcije in simulacije Prediktivno alarmiranje okvar Korektivni in kurativni ukrepi Samoučeči algoritmi Dinamična, hitro prilagodljiva proizvodnja na nove zahteve trgov -> kratki časi prehoda iz razvoja v proizvodnjo Zelene tovarne prihodnosti
8 Možne smeri iniciative Industry 4.0. za tovarne Fokus na izdelke Rešitve za stranke v oblaku: Portal za stranke Dostop do izdelkov in končnih strank Optimizacija vzdrževanja Korektivni in kurativni vzdrževalni ukrepi Hiter odziv Alarmiranje Daljša garancija Vpogled v obnašanje izdelkov Varen dostop do podatkov Integracija z drugimi sistemi/napravami pri strankah
9 Metronik Industry arhitektura Predikcija in simulacije WEB Analitika Vizualizacija in monitoring Povezava na druge IT sisteme (ERP, ) Kontekstualizacija Arhiviranje podatkov Varen zajem podatkov Ethernet
10 Metronik Industry arhitektura Predikcija in simulacije WEB Analitika Vizualizacija in monitoring Povezava na druge IT sisteme (ERP, ) Kontekstualizacija Arhiviranje podatkov Varen zajem podatkov Ethernet
11 Varen zajem podatkov Različni podatkovni viri: Procesni sistemi Telemetrijski sistemi Pametni senzorji, IoT ready PLC (GE, OPTO22, Siemens) MePIS klienti za zajem: Ročni vnosi Zajem datotek Bazna povezava Spletni servisi OPC UA Varen prenos podatkov: HTTPS VPN tunnelling Sinhrona in asinhrona komunikacija GE Cybersecurity rešitve SW HW
12 Metronik Industry arhitektura Predikcija in simulacije WEB Analitika Vizualizacija in monitoring Povezava na druge IT sisteme (ERP, ) Kontekstualizacija Arhiviranje podatkov Varen zajem podatkov Ethernet
13 Arhiviranje podatkov Podatkovni tipi: Surovi procesni podatki (podatki s časovni značko) Alarmi in dogodki Podatki o seriji/delovnem nalogu Recepture Procesni dogodki Datoteke poročila procesne opreme (pdf, txt, xml, ) Načini stranjevanja: Procesna baza GE Historian Relacijska baza SQL Server
14 GE Historian Agregacija in kontekstualizacija Procesni kontekst 1:00pm Tank Temp 60 C 1:01pm Tank Temp 62 C 1:02pm Tank Temp 64 C 1:03pm Tank Temp 59 C
15 GE Historian statistične funkcije First, last, min, max, count, total, average, standard deviation
16 GE Historian filtri
17 GE Historian Izvoz podatkov
18 Metronik Industry arhitektura Predikcija in simulacije WEB Analitika Vizualizacija in monitoring Povezava na druge IT sisteme (ERP, ) Kontekstualizacija Arhiviranje podatkov Varen zajem podatkov Ethernet
19 Kontekstualizacija Podatki so organizirani v hierarhičnem drevesu s poljubnim številom nivojev Podpora za več drevesno strukturo organizacije Vgrajen model S95 Poslovni podatki v so v korelaciji s procesnimi podatki
20 MePIS PDM Podatki so organizirani v hierarhičnem drevesu
21 MePIS PDM Analitika korelacij
22 MePIS PDM Primerjava serij
23 MePIS PDM Primerjava alarmnih podatkov
24 Metronik Industry arhitektura Predikcija in simulacije WEB Analitika Vizualizacija in monitoring Povezava na druge IT sisteme (ERP, ) Kontekstualizacija Arhiviranje podatkov Varen zajem podatkov Ethernet
25 Vizualizacija in monitoring Spletna tehnologija - HTML5 brez namestitev pri odjemalcih Predpripravljena vsebina: OPEX (zastoji, KPI, monitoring, poročila, OLAP analitika) Energetska učinkovitost (monitoring, izračuni, CUSUM, M&T diagrami) Ravnanje z odpadki, emisijska poročila Podpora vzdrževanju (korektivni in kurativni ukrepi) Primerjava podatkov Alarmiranje Konfiguracija poljubnih vsebin (brez programiranja) hiter razvoj Poročila
26 Za vodje izmen/oddelkov
27 Za operaterje Select Reason button to open downtime entry screen Button to navigate back to the above screen
28 MePIS OPEX Dostop do podatkov v realnem času
29 MePIS OPEX Identifikacija težav in možnosti za izboljšanje procesa
30 MePIS OPEX
31 MePIS OPEX
32 MePIS PDM
33 MePIS PDM
34 Metronik Industry arhitektura Predikcija in simulacije WEB Analitika Vizualizacija in monitoring Povezava na druge IT sisteme (ERP, ) Kontekstualizacija Arhiviranje podatkov Varen zajem podatkov Ethernet
35 GE Predix: Razvit za potrebe industrijskega IoT Hybrid Cloud-based platforma za industrijski internet Optimiziran za zahteve iz proizvodnje Connected Assets Industrial Data Management Asset Performance Mgmt Operations Optimization Industrial Data Science Cloud & Mobile Industrial Analytics Digital Twin! Reliability Increase availability and longer asset life Cost Reduction Lower operating costs with greater efficiencies Risk Mitigation Lower operations and financial risk Profitable Growth Increase production for market advancement 35
36 36
37 Metronik Industry arhitektura Predikcija in simulacije WEB Analitika Vizualizacija in monitoring Povezava na druge IT sisteme (ERP, ) Kontekstualizacija Arhiviranje podatkov Varen zajem podatkov Ethernet
38 Predikcija in simulacije GE CSence Mathlab Namenske rešitve razvite v sodelovanju z laboratorijem UNI LJ - FE
39 Procesni KPI CSense Trenutne performance Optimalne performance Optimize Process 1. Iskanje informacij v podatkih Iskanje vzrokov za zastoje in variacije v procesu 2. Konfiguracija formul ali prediktivne analitike Čiščenje in transformacija surovih podatkov 3. Konfiguracija optimizacijskih algoritmov Ukrepi za optimalen nadzor na procesov
40 CSense
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