Mitsubishi Electric and the Future of Monozukuri (Manufacturing) May, 2016 Mitsubishi Electric Europe B.V. Kazuaki Miyabe
Monozukuri Evolving Responding to Environmental Changes The following shows examples of the IT and information infrastructure evolution. Data communication technology High-speed communication Data collection technology Sensing Data analysis technology Artificial intelligence Device-to-device communication Efficient collection Simulation
"Monozukuri (Manufacturing)" Using Digital Space In the future Monozukuri, digital space will be more frequently used in each process. Market info. Analysis Process in factory Product development Design Trial Evaluation Production Test Packing Shipment Market info. collection Trend prediction 3D design Virtual reality Reliability prediction Simulation evaluation Machinability evaluation 3D printer Evaluation data accumulation Failure analysis/ feedback Automation Monitoring Quality analysis/feedback Equipment preventive maintenance Consumption energy management Automatic packing/ shipment Delivery planning Individual identification Traceability Digital space Besides the above: [Marketing info.] Demand prediction from market/environmental information Production instruction [Sales info.] Optimal procurement [Logistics] Optimal transport, carrier arrangement [Maintenance] Life prediction, trend management, prevention plan maintenance Digital space will streamline and shorten processes.
Mitsubishi's Efforts - FA integration solution - Basic concept e-f@ctory uses both technologies of FA and IT for offering solutions to reduce total cost of development, production, and maintenance and to support advanced Monozukuri. <Production site optimized by > Collecting production-site data in real time Seamlessly linking data collected through FA with the IT system Feeding back analysis results from the IT system to production sites We introduce e-f@ctory, which connects FA and IT.
FA Integrated Solution This solution improves Productivity Quality Environment Safety Security through Visualization with analysis Improvements Increased availability at production sites It assists companies to reduce TCO and to improve the company values. Productivity improvement Security Quality improvement Safety improvement since 2003 Environment improvement Visualization with analysis and improvements
This solution organically connects all systems related to the factory production, quality, and safety via networks to visualize what is happening and where it is happening. The data captured through this visualization allows optimal management. Analysis IT system Simulator SCM ERP SCADA CAD CAM FA-IT interface FA-IT linkage FA-IT info. interface Feedback Production site Controller Drive Energy-saving Mechatronics Collecting realtime info. on manufacturing sites
Necessary Elements for Offers the technologies for achieving data link among software applications Simulator SCM ERP Means for linking devices to various software applications for production management, quality management, etc. are required. SCADA CAD CAM FA-IT info. interface Controller Drive Energy-saving Mechatronics Means for figuring out what is happening at production sites promptly, correctly, and efficiently are required. Offers networking technologies including sensors
e-f@ctory Alliance Partners familiar with problems offer the best solutions. SI partners Support production-site construction/operation. Software partners Offer software required for collection/analysis/management. SI partners System Integration Partner Software partners Software Partner Device partners Device partners Device Partner Offer devices required for measurement/ control. No. of participants: 300 companies (including both inside/outside Japan) (as of the end of Oct, 2015) Partners having abundant experience/technologies in various fields
Application Examples of Over 5,200 e-f@ctory systems are operating in over 130 companies worldwide. (spreading globalization/overseas factories) e-f@ctory is supported by customers in various fields, such as automobile, solar battery, secondary battery, precision equipment, semiconductor, food, metal processing.
History of Industrial Internet is coined Partner program expanded Winner of Frost and Sullivan Best Practice Award Foundation open technologies First mention of IoT as a concept First partners 2000 The first Innovative, PCless connection 1GBPs Industrial shop floor to MES network technology connection released 2003 Official release 2005 model factory deployed at Mitsubishi Electric,Nagoya Japan 2007 Hit 2000 members 2009 ARC white paper on e-f@ctory 2011 2013 model factory Fukuyama, Japan 2015 First mention of Industrie 4.0 model factory Gunma, Japan Changshu, China model factory Kani, Japan
Solution example of e-f@ctory -Introduction Example of e-f@ctory -Robot assembly cell system at Kani Factory- Management of individual data and utilizing in next process to realize optimum production. Productivity 30% Up Read operating instructions Remove manual settings Prevention of assembly errors Shipment test Elimination of test failure(manage test data) Screw tightening by Servo Elimination of screw tightening failure(control torque data) Production Ratio 60% Up Laser printing Error of name plate and model name Elimination failure of ink printing Control test data Early identification and improvement for cause of failure Number of processes 55% Down Operating instructions Prevention of contact arrangement error Operating instructions Prevention of contact components error Also realizing traceability after shipment Mitsubishi Electric Read component information Speed up setup countermeasures for bad lots Area Ratio 85% Down
Application Example (Preventive Maintenance System for Production Equipment) Manufacturing Execution System (MES) Equipment A preventive maintenance system for production equipment using the IoT technology has been developed. Press release together with Intel Corporation (on Sep. 29) (http://www.mitsubishielectric.co.jp/news/2014/0929.pdf) The system was introduced to Intel's semiconductor production line (Malaysia) in 2013 on trial and improved the yield, reducing the annual cost by about 9 Million USD. MES Information (SECS/GEM) Instruction data from the execution system to link the data of 1) IoT Gateway 2) Compiled data (FTP, SECS) C controller (Mitsubishi Electric) + Process data measurement/ monitoring (NIPPON DENNO CIMSNIPER) 1) 3) Data analysis software (Revolution Analytics product) 1) Sensor/analog data is collected through the network (CC-Link IE). 2) The primary processing is conducted at the IoT gateway (C controller) and the data is sent to the IT layer. 3) The data is analyzed with R language (Revolution R). SECS: SEMI Equipment Communications Standard GEM: Generic Equipment Model