EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 1
Linked Engineering and Manufacturing
Dimitris Kiritsis
EPFL, ICT for Sustainable Manufacturing
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 2
Some words about DK…
• STI-IGM
– Prof. ICT for Sustainable Manufacturing
• School of Industrial Engineering – Grenoble INP
– Member of the Board (2nd mandate)
• EC – AG LEIT-NMBP
– Individual Member
• IFIP WG5.7 – Advanced Production Management Systems
– Chair
• Member (representing EPFL)
• Member of the advisory board www.cl2m.com
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 3
ICT for Sustainable Manufacturing
Optimisationof Lifecycles
of Product Systems
SYSTEMS ENGBusiness Process ModelingFunctional Modeling…
OPERATIONS RESEARCHPetri NetsGraph TheoryStatistical Analysis…
Sustainable Manufacturing involves a complex system of Products, Processes and Ressources need for multidisciplinary research
Main disciplines:•MECHANICAL ENG
•MANUFACTURING ENG
•LIFECYCLE MANAGEMENT
COMPUTER SCIENCEOntology Engineering / Semantic WebInternet of ThingsKnowledge Management /AI
Data miningData AnalysisReasoning…
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 4
What must be “sustained” in manufacturing ?
• Performance, Quality and Safety
• Natural resources and Environment
• Lifecycle thinking
• Human Capital and Education
• Innovation
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 5
Lifecycles
MOL
Assembly
Part Manufacturing
Procurement
BOL
Detail Design
Life Cycle Planning
EOL
Disposal
Parts/Component reuse
Collection (Reverse logistics)
Life Cycle Conceptual Design
Distribution (Logistics)
Maintenance (Service)
Use
Material recycleDesign Production
Lifecycle DB/KB
PLMPlatform
Lifecycle dataLifecycle data
Lifecycle data
Remanufacturing
(DisassemblyRefurbishment,
Reassembly,Test, etc)
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 6
MOL
Process
Resource
Product
DESIGN
Process
Resource
Product
PRODUCTION
Process
Resource
Product
EOL
Process
Resource
Product
Materials
Disposal
Recycling
Re-mfg.
Service Re-use
Closing the information loops
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 7
CL2M: Closed Loop Lifecycle Management for Industry 4.0The PROMISE Concept
- Data
Embeddeddevice
- Diagnosis- Decision making
- Data
- Info
- Info
- Info request
- Info- Advice
PEID(CPS enablers)- Sensors- Tags- Memory- Data
Wireless comm.(short distance)
Internet(long distance)- Semantics
- Ubiquitous computing
- PLM agent- Knowledge agent- DFX agent
Producer’sPDKM
© EPFL
- Product/Asset with
- PLM Agent
In the Cloud- PLM system- KB repositories
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 8
Applications
PEID
RFID
Middleware
Data Services
EmbeddedSystems
Read/Write
Business
Processes DecommissioningBusiness
Processes
ProductsProducts
Design/Production
Design for X PreventivePredictiveMaintenance
Tracking &Tracing
Adaptive
Production Effective Recycling
Semanticenrichment
Dispatching
NotificationsPEID
Management
AnalyticsKnowledge
ManagementDecisionMaking
A system architecture for Industry 4.0
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 9
CL2M system architecture for Industry 4.0
Data analytics and transformations (Middleware)
Data gathering (PEID)
Business applications
BOL MOL EOL
(1) Horizontally closed
Seamless Lifecycle Data-Information-Knowledge Transformations
- Gathering data- Feedback
- Information, Knowledge- Feedback
(2) Vertically closed
Applications
PEID
RFID
Middleware
Data Services
EmbeddedSystems
Read/Write
Business
Processes DecommissioningBusiness
Processes
ProductsProducts
Design/Production
Design for X PreventivePreventiveMaintenance
Tracking &Tracing
…Adaptive
Production …Effective Recycling
Semanticenrichment
Dispatching
NotificationsPEID
Management
AnalyticsKnowledge
ManagementDecisionMaking
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 10
PEID & CPS
IoT
Key Enabling IC Technologies for CL2M
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 11
PEID
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 12
PEID architecture
PEID
Long range communication
Short range communication
Product identification
Data storing
Power unit
Sensor reading unit
Memory
EPC
Radio wave
Data processing/diagnosis
Internet/GSM/GPRS/Mobile phone
Embedded SW
Data gathering
Power management
PassiveRFID
ActiveRFID On-board
Com.
• PEID stands for ‘Product Embedded Information Device’.• Depending on product types and application area, there are various kinds of information devices built in products to gather and manage product information.
Source: Kiritsis, ch. 5.4, Springer Handbook of Automation , 2009
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 13
IoT
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 14
The new IT pyramid
• Each Enterprise has «his own» pyramid.• All parts not always needed.• PLM, CPS, ERP and IoT play key roles.
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 15
Systems of Systems
System?
System?
System?System?
System?
System?
System?
System?
System?
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 16
IoT today
• Sensor data pushed to virtual/real servers
• Data collected into vertical silos
• M2M communication limited to local networks
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 17
IoT today: challenges
• Huge amounts of data (Big Data) collected that is difficult to use
• Interoperability is hard to achieve, even with REST APIs
• IoT should not be just local M2M
• IoT should not be just machine-to-cloud communication
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 18
IoT with Open Group Standards
• Systems rather than sensors
• Horizontal integration as easy as vertical integration
• Connections created without programming as needed
• Establish two-way, time-limited information flows between trusted entities and the physical product(s)
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 19
Standards of IoT Work Group
• Published by The Open Group on October 16th, 2014
• Open Messaging Interface (O-MI): communication
• Open Data Format (O-DF): payload
• May be used independently of each other (as HTTP and HTML)
• Publish available information and services
• Discover availableinformation and services
• Read/write of immediate and historical information, alerts, other events, …
• Subscribe to information using Observer Design Pattern
• Specified using XML schema
• Can be transported by ”any” underlying protocol: HTTP, HTTPS, FTP, SMTP, XMPP, file transfer, USB sticks, plain sockets, …
• Usable as Standardized IoT REST API as well as M2M, M2S etc.
Format
XML,XML schema, JSON,HTML
O-DF
OSI ModelLower Layers
Communication
HTTP(TCP/IP, SOAP, SMTP, …)
O-MI
Web
Application
Ap
plic
atio
n L
ayer
IoT
http://www.opengroup.org/getinvolved/workgroups/iot
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 20
Open Lifecycle Management
• O-LM: Open Group (Things) Lifecycle Management: Exchange information about ”Smart Things (or smart products)” that are generated across the whole Lifecycle Phases, using a well defined format
• Currently used to exchange data about components & materials, operations and transformations and data acquired by the physical product
• Format defined and approved internally to IoT WG, formal accompanying document in progress
http://www.opengroup.org/getinvolved/workgroups/iot
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 21
Systems of Systems: Closed-Loop Lifecycle Management (CL2M)
Instance
Manufacturing 1
Manufacturing 2
User 1
User 2
Recycling
InstanceInstance
Instance
Instance
Product informationWhere? In one or many places?Type/version/instance-specific?
Information queries/updates
Designer 1
Designer 2
”Thing”
”Thing”
”Thing”Business
idea/planIoT
• Lifecycle view: IoT is about managing all information about any product/Thing
• Information is Distributed over Systems (devices, servers, applications, ...)
• Information is Distributed over Organizations (companies, individuals, authorities, …)
• Product (and its parts) are unique instances
• How manage identities, access rights, …?
• IoT should provide necessary Capabilities for CL2M
Red arrows: O-MI & O-DF
www.cl2m.com
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 22
Applications in current H2020 & FP7 projects
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 23
10/11/201623
Linked Engineering and Manufacturing
Data Federation
• Relevant information, across trusted sources in the product lifecycle
• Format, location and time independent
Context-driven access and analysis
• Collaborative charting and simulations
• Integrated information analysis
User collaboration
• Extension of lean engineering principles
• Collaboration workbench for effective internal and external collaboration
Feedback into existing systems
• Tight connection to the federated systems
• Push-back of enriched information
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 24
10/11/2016Adrian Mocan, SAP AG24
LinkedDesign Achievements
• Problem and role-specific information presentation
• Modular, reusable, self-contained logical info units
• Collaboration along the full product lifecycle
• Enabling the human factor
• Domain specific ontologies
• Novel use of algorithms for LCC and LCA
• Domain specific techniques
• Data federation by semantic mediation
Data Integration
Data to Information
Information to Presentation
Knowledge Integration
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 25
LinkedDesign Ontology
10/11/2016 25
isSpecialization
isSpecialization
isSpecialization
Product DefinitionLifecycle Cost Assessment
Ontology
Product DesignDesign Knowledge Ontology
Product manufacturing Quality Control Ontology
Generic and lightweight Reusable in different
industrial applications
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 26
LinkedDesign Upper Ontology - LDO
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 27
LinkedDesign Network Ontology
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 28
10/11/2016Adrian Mocan, SAP AG28
Use cases
ApplicationPrototypes
Demon-strators
Manufacturing Design based on
Plant Lifecycle Costs
Knowledge Reuse and Collaboration in Automated Design
for Offshore Engineering
Metrology-driven Manufacturing in the Automobile Industry
Automated Design with
Virtual Obeya
Lifecycle Design Optimisation
Manufacturing Quality Control
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 29
COMAU
Product LifecycleOptimization Tool
Data source: Customer Specs.Sensor values
Implemented usingSWRL
Base set of 20 rulesdefining calculationof parameters and relevant set of design constraints
- Support LCA of production line
- Monitor the performance of the line in operational phase
- Calculation of MTTR, MTBF, availability, down time...
- Optimal values for parameters: MTTR, MTBF…
Use case requirements
KnowledgeCapture
KnowledgeConceptualization
ImplementationInteraction with
LEAP
Inference Analysis
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VW-TRIMEK
- Identification of risky parts
- Crack detectionin hot stampingprocess
Optimal values for each parameter: Oven temp., Dwelltime, Insertion and extraction temp., Pressing force, etc.
Production Line Real Time Monitor
Data: Sensor values
Base set of 20 rules defining tolerable deviation of real measured values compared to optimal
Implemented usingSWRL
AKER
- Semanticenrichment of engineering standards
- Recommendationbased on the business context
- Industrialstandards handling and application
- K-briefmaintenance
Base set of 10 rules for K-briefs and set of 27 rules as an examplefor standards usage
Implementedusing SWRL
Concept level- Virtual K-Briefs
Data: Design parameters, K-Briefproperties/
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 30
Inference Analysis
Instance Importer
Semantic Reasoner
Base set of rules
If|HotStamping.Optimal.OvenTemp[14]-HotStamping.AsMeasured.Heating.Temperature[14]|>20C then ConsideredRisky=1
If HotStamping.AsMeasured.Heating.DwellTime > HotStamping.Optimal.DwellTimethen ConsideredRisky=1
If |HotStamping.Optimal.BlankholderForce -HotStamping.AsMeasured.Heating.BlankholderForce| > 20 then ConsideredRisky=1
If HotStamping.Optimal.InsertionTemp -HotStamping.AsMeasured.Heating.InsertionTemp < -20C then ConsideredRisky=1
If |HotStamping.Optimal.PressingForce -HotStamping.AsMeasured.Heating.PressingForce|>50KN then ConsideredRisky=1
If HotStamping.Optimal.CycleTime - HotStamping.AsMeasured.Heating.CycleTime > 2s then ConsideredRisky=1
If |HotStamping.Optimal.ExtractionTemp-HotStamping.AsMeasured.Heating.ExtractionTemp|>20°C then ConsideredRisky=1
If HotStamping.AsMeasured.TimeStamp > 0.95*Tool.MaintenancePeriod then ConsideredRisky=1
…
Production Line Real Time Monitor
1
2
3
4
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 31
Data correlation and pattern discovery
Proposed methodology
Pre-Processing
• Dealing with missing values , categorical attributes , outliers , etc.
• Supported using LDO and inconsistencychecking
Correlationdetection
• Calculation of correlations between attributes
Modeling
• Application of classification algorithms for pattern discovery (DT; K-NN; SVM)
Reporting
• Generating text files that contain relevant findings
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 32
Ontology for quality control in hot-stamping
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 33
Sources of information & data
Two sources of information about source of defects
Workers experience Heuristics
Data analytic and data mining of existing data bases
Both are integrated to create automatic alert system for increased quality level risk
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 34
Toolset for correlation analysis
• Statistical tests are performed on all pairs of attributes
1. Numerical & Numerical : Pearson’s coefficient
2. Numerical & Categorical : Davies-Bouldin index
3. Categorical & Categorical : Chi-squared test
• Threshold of “significance” are predefined as threestandard deviations distant from mean value of allcorrelations for given pair
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 35
Architecture of Data modeling module
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 36
Decision tree for quality control in hot-stamping
Data analytics is performed directly on instances populating the ontology
High risk ! High risk !Norisk
High risk !Norisk
Yes
Yes
Yes
Yes
No
No
No
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 37
The intelligent consumer/user in the loop …in the Product Lifecycle loops
Designer / Producer
Consumer /User
ServiceProvider
D, I
K
D, I
D, I
IoT&
PEID(CPS enablers)
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 38
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The FALCON H2020 FoF project
FALCON will define and deploy a Virtual Open Platform for Product/Service Design, Manufacturing and Lifecycle Management
FALCON will investigate how user experiences and usage data collected via IoT and social media can be deployed for the improvement and design of product-services.
The Virtual Open Platform platform will incorporate new simulation techniques and benefit from a semantic representation of PLM information for cross-sectoral search
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 39
• FALCON Virtual Open Platform• Open system-architecture defined • Systems of Systems Approach • Based on semantic technologies
• Initial FALCON Ontology• Initial definition of upper ontology covering PSS
knowledge domain• Initial definitions of domain-specific ontologies for
FALCON business scenarios
• GUI Mockups & Business Stories• Development of detailed Business Stories• GUI Mockups facilitate understanding of functionality
• Software prototypes of Functional Modules• E.g. data federation module for knowledge acquisition
from static PUI sources (PEIDs, social media, etc.)
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FALCON Achievements (…so far)
VOP PUI Manager
Aut
horiz
atio
n an
dA
cces
s C
ontr
ol
SPARQL EndpointPub/Sub Query Endpoint
JDBC Endpoint
Linking Component JDBC Interface
Triple StoreRDF Stream
View ManagerFALCON Data
Federation Module
FALCON KBE
Mapping Tool
FALCON KCCM
Management Tool
Social Media Wrapper
Legacy System
Wrappers
KCCM
PEID Stream Wrappers
Structured Data Source
Wrapper
Social Media Stream
Wrapper
FALCONIdea Manager
FALCONSimulation and
Forecasting Manager
FALCONPUI Query Builder
FALCONData Visualisation
Module
FALCONData Export
Module Mediator
ConfiguratorStream
Manager
FALCONOntology
VOPLogin
3rd Party LCA Tools
CAx ToolsSimulation
Tools
OtherTools
FALCON PUI Alert Module
PEID Wrappers
VO
P In
fras
truc
ture
S
ervi
ces
FALCON Open API
Virtual Open Platform – Final Draft Architecture (30.06.16)
WP2
WP3
FALCON Collaborative PSS Design Solution 3rd Party Software
WP4
WP1
FALCON Virtual Open Platform Core 3rd Party
FALCON PUI Wrappers
Legend
Interface
Defines/uses
Brown GoodsWhite Goods
Healthcare Products
Clothing TextilesHigh-tech Products
isSpecialization isSpecialization
isSpecialization
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 40
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Business Scenarios
Clothing Textiles
Business Motivation:
Integration of data sources and creating valuable information to help offering customers
A better product-service quality through optimization of planning, development and testing processes.
New innovative services for existing products.White & Brown Goods
Business Motivation:
Improve collection of feedback from customers from usage phase and even from new collection proposals
Improve exchange of information both from social networks, marketplaces and our e-commerce site.
Collecting better information about required fitting of the garments.
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 41
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Business Scenarios
High-tech Products
Business Motivation:
Increase technical reliability of the devices,
Enable comprehensive diagnostics, and
Enable user-friendly devices and services
Healthcare Products
Business Motivation:
Identify potential demands for equipment before the bid is out (customising needs)
Increase the Competitiveness of Metrology Solutions improving their functionalities and ease to use.
Reinforce Client “loyalty“ offering metrology services
more effective.
Improve the Calibration, Maintenance & Verification processes and Enhance Machine Programming & Report Content Definition.
EPFL/STI/IGM/ICT for Sustainable Manufacturing @ EMS Summit 2016/ 05.10.2016 http://ict4sm.epfl.ch/ 42
Taking the LEAP …
10/11/201642