Apr. 15th, 2015
Future Manufacturing and FA Integrated Solution “e-F@ctory” Dr. Kazuhiro Kusunoki General Manager, e-F@ctory Strategic Planning Project Nagoya Works COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
Mitsubishi Group Overview Mitsubishi group of companies Mitsubishi Electric Corporation
Mitsubishi Heavy Industries, Ltd.
Electric & Electronics
Mitsubishi Corporation
Mitsubishi Motors Corporation
Nikon Corporation
Automobiles
Cameras, Optical, Equipment
Ships, Aircraft, Turbines
The Bank of Tokyo-Mitsubishi UFJ,Ltd.
Tokyo Marine & Nichido Fire Insurance Co., Ltd.
Kirin Holdings Co.,Ltd.
Nippon Yusen
Global logistics
Trading
Banking
Casualty, Insurance
Totally 217 companies belong to Mitsubishi Group. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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Mitsubishi Electoric Overview
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FA System Group Overview Controller products →work like human brain and face
PLCs HMI (Human
Drive Products
AC Servos
→work like human arms and legs
Inverters
Machine Interface)
Three phase motors NC (Numerical Control)
Mechatronics Products
Electrical-Discharge Machines
→machine tools /robots (work instead of workers)
Laser Processing Machines
Power distribution control products
Electromagnetic Switch
→control power distribution
Robots
Transformer No Fuse Breaker, Earth Leakage Breaker COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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FA System Group Overview Overseas offices
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Solution for advanced factories of the future
1. Future Vision of Monozukuri (Manufacturing) 2. FA Integrated Solution e-F@ctory
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"Monozukuri(Manufacturing)" according to Environmental Changes The following shows evolutions of the ICT and information infrastructure. Data communication technology High-speed communication
Device-to-device communication
Data collection technology
Data analysis technology
Sensing
Artificial intelligence
Efficient collection
Simulation
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"Monozukuri(Manufacturing) " using Digital Space
Market info. Analysis
・Market info. collection ・Trend prediction
Process in factory Product development /Design
Trial /Evaluation
Production /Test
・3D printer ・3D design ・Evaluation data ・Virtual reality accumulation ・Reliability prediction ・Failure analysis ・Simulation evaluation /feedback ・Machinability evaluation
Packing /Shipment
・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 info. → Production instruction [Sales info.] Optimal procurement [Logistics] Optimal transport, carrier arrangement [Maintenance] Life prediction, trend management, preventive plan for maintenance
Using Digital spaces, each process work efficiency and shorten term. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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Next-generation "Monozukuri(Manufacturing)“ that "Humans" realized with Machines
Only "humans" can "realize" design data simulated on digital space. "Humans" suitably use things optimized in digital space to optimize "Monozukuri(Manufacturing)". Digital space
Supplies the optimal data created in digital space to robot systems/humans.
Feeds back unpredictable "awareness/experience/know-how".
Real
Realize design data and adjust/improve (On-site knowledge)
Only "humans" can fill gaps between reality and virtual space. Only "humans" can improve higher quality. Only "humans" can find improvements. Digital space shortens distance to the ideal but cannot give perfect solution. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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A solution for advanced factories of the future
1. Future Vision of Monozukuri (Manufacturing) 2. FA Integrated Solution e-F@ctory
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Mitsubishi's Efforts - FA integrated solution
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Basic concept
The major concept is “TCO*" across development/ manufacturing/maintenance. This solution optimizes factories using advanced technologies/information to support the future of Monozukuri(Manufacturing).
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• Collecting production-site data in real time • Seamlessly link the collected data in FA with the ICT system • Analysis results according to the ICT system are feed back to production sites
*TCO:Total Cost of Ownership
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FA Integrated Solution This solution improves "productivity", "quality", "safety", and "environment" through visualization at production sites and assists companies to reduce TCO and improve the company values.
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This solution organically connects all systems via network related to the production, quality, and safety in the factory to visualize what is happening and where it is happening. The data captured through this visualization allows optimal management. Analysis
FA-ICT interface
ICT system
SCM
ERP
SCADA
CAD
CAM
FA-ICT linkage
Production site Collecting realtime info. on manufacturing sites
Simulator
Controller products
FA-ICT info. interface products
Drive products
Energy -saving products
Feedback
Mechatronics products
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Necessary Elements for
Need methods for linking various PLM tools
Need methods for figuring out what is happening at production sites promptly, correctly, and efficiently COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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Problems and Solutions at Production Site Various engineering tools (development environment, monitor tool, etc.) are prepared according to the characteristics of equipment/devices at production sites, and connected via various FA networks. The integrated software (iQ Works) and seamless linkage protocol (SLMP) offer to realize an integrated environment.
CAD
Simulator
CAM
Engineering tool
EZSocket CSP+
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FA Network Connecting Lines, Equipment, and Devices , high-speed/large-capacity communication
A large amount of control/quality/manufacturing information at production sites can be processed at high-speed/large-capacity of 1 Gbps in real time. = Message communication (transient communication) = Access to shared memory
Production instruction, manufacturing/quality info. (massage communication)
Bottling process
Control info. (network shared memory)
Packing process
Even a large amount of quality/manufacturing info., it will not affect transmission of control info.
Control/production/quality info. at production sites can be "visualized", and analysis will be easy. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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SLMP SLMP (SeamLess Message Protocol): Common protocol that provides seamless device communication regardless of network types/hierarchies
Computer level
Ethernet Info. communication
Seamless info. linkage
CC-Link IE Control
Controller level
Controller distributed control
CC-Link IE Field Device level
CC-Link AnyWire ASLINK I/O control
CC-Link Safety Safety control
SSCNET Motion control
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ICT Linkage Technology Various applications can be operated in the ICT system, such as ERP, MES, schedulers, and simulators. Simulator
SCADA Simulator
SCM
ERP
MES
CAD
CAM
Database, ORACLE, SQL Server, etc.
ERP SCM
SCADA
MES CAD CAM
Direct connection Network fault processing : Buffer memory : Automatic refresh
Automatic setting of collection time info.
Adoption of this architecture is postponed because of the expandability and versatility. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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Information Interface Products Information interface products eliminate PCs/programs from processes of on-site information collection (FA → ICT) and processes of information spread from information systems (ICT → FA). MELSEC-Q PLC MES Interface
MES Interface IT for MELSEC-Q PLCs
GOT2000/1000 HMI MES Interface
PLCs are connected directly to the MES without the use of gateway PCs or communication programs.
Greater compatibility with diverse platforms and databases ensures direct connections between the shop floor and information systems.
The GOT2000/1000 HMI collects and sends data from connected FA products to the MES.
Data collection analyzer MELQIC MES Interface
Production and inspection information of production sites can be collected in real time.
High-speed Data Logger Module for MELSEC-Q PLCs
Designed specifically for MELSEC-Q Series PLCs, the new data logging module can be easily installed in the PLC CPU and set up to provide efficient data logging solutions.
BOX data logger
To the system that has already operated and is operating, this module can be additionally installed, allowing data collection of the system.
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e-F@ctory Alliance Mitsubishi Partners to be familiar with problems offer the best solutions. SI partners Total Support for the construction/operation on production-site
Software partners Offer software required for collection/analysis/management.
Device partners Offer devices required for measurement/control.
No. of participants: 282 companies (including both inside/outside Japan) (as of Feb.2014)
Partners having abundant experience/technologies in various fields COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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Solution by utilizing ICT e-F@ctory : Production efficiency by using digital space in the phase of design, production and maintenance Design phase Utilize CAD for machine simulation : Interference check : Operation verification
Production phase Utilize schedule system for production planning : Best approach for production planning
Digital space
Maintenance phase Utilize data logging : Implementation of traceability : Troubleshooting quickly
“Digital space” will be used more and more for Monozukuri (Manufacturing) COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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EPLAN(Software Partners) EPLAN Data Portal ①EPLAN supports Mitsubishi FA products information Easy to check : Line connection, interference Easy to calculation : Line length ②Support of label exchange between EPLAN and iQ Works (Development:2015-2016) Advance : Design efficiency, Quality ③Auto generation of system configuration (I/O assignment, Network Parameter) in iQ Works Advance : Design efficiency for utilize of Electrical CAD drawing
Electrical CAD drawing
Mitsubishi FA Products macro
Import macro data
EPLAN
iQ Works (GX Works3)
Signal name can be exchanged between EPLAN and iQ Works
Electrical CAD drawing
iQ Works system configuration
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History of 2011 2008
2003 2000
2014
[2005] Nagoya [2010] Fukuyama [2012] Kani [2013] Gunma Model plant [2013] Changshu, China
2006
2008
MES Interface IT
2007
2006 2005
2003
C Controller
GOT-MES
MES Interface module
e-F@ctory concept release COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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Application Examples of
Over 5,000 e-F@ctory systems are operating in over 100 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. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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IoT/Big Data Compatibility, Architecture of The keyword is ... Adopting approaches to Big Data advocated by ICT companies is difficult for manufacturing sites Various data is generated at production sites. (Data is generated in many facilities at different cycles.)
On-site knowledge is required to understand the data and correlations.
Integrated analysis/ optimal management/ Remote diagnosis
Local analysis/optimal production Quality management
The best data-processing architecture is the e-F@ctory, in which primary data processing is conducted at production sites. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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Application Example (Preventive Maintenance System for Production 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 hundred million yen.
MES Instruction
Data analysis software (Revolution Analytics product) Instruction + Sensor data
Process data measurement/monitoring (CIMSNIPER produced by NIPPON DENNO) Primary data processing
Instruction
Various sensor data
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Future Prospects Necessary information can be Accessible from Anywhere Anytime Smartphone
PC
Tablet
Allow remote monitoring about operating status of equipment and instructions to the maintenance workers. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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Future Prospects Equipment Data Collection/Analysis on the Real-time
Reactive
Proactive
Predictive
Production efficiency(JIT) will be realized through real-time collection/analysis on production/energy data. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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Future Prospects Shift from Production Phases to Entire Industry
Improve the company value by improving productivity/quality/product value and conducting social contribution through energy saving.
Company and production activities link seamlessly to respond to market/situation changes. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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for Promoting "Monozukuri(Manufacturing)" We evolve e-F@ctory with accumulated know-how for the "Monozukuri(Manufacturing)" future.
We will widen the scope of e-F@ctory and enhance the functions with our partners. COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED
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