future manufacturing and fa integrated solution...

COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED

Dr. Kazuhiro Kusunoki General Manager, e-F@ctory Strategic Planning Project

Nagoya Works

Future Manufacturing and FA Ｉｎｔｅｇｒａｔｅｄ Solution “e-F@ctory”

Apr. 15th, 2015

2 COPYRIGHT@2015 MITSUBISHI ELECTRIC ALL RIGHTS RESERVED

Mitsubishi Group Overview

Mitsubishi Heavy Industries, Ltd.

Mitsubishi Electric Corporation

Totally 217 companies belong to Mitsubishi Group.

Electric & Electronics Ships, Aircraft, Turbines Automobiles

Trading Banking

Cameras, Optical, Equipment

Casualty, Insurance

Nikon Corporation

Mitsubishi Corporation

The Bank of Tokyo-Mitsubishi

UFJ,Ltd.

Tokyo Marine & Nichido Fire

Insurance Co., Ltd. Nippon Yusen Kirin Holdings

Co.,Ltd.

Mitsubishi group of companies

Mitsubishi Motors Corporation

Global logistics


Mitsubishi Electoric Overview


FA System Group Overview

PLCs

ＨＭＩ（ＨｕｍａｎＭａｃｈｉｎｅＩｎｔｅｒｆａｃｅ）

Three phase motors

AC Servos Drive Products

Power distribution control products

Mechatronics Products

Inverters

No Fuse Breaker, Earth Leakage Breaker

Electromagnetic Switch

Electrical-Discharge Machines Laser Processing Machines

NC （Numerical Control）

Robots

Controller products

Transformer

→work like human brain and face

→work like human arms and legs

→machine tools /robots （work instead of

workers）

→control power distribution


Overseas offices FA System Group Overview


1. Future Vision of Monozukuri (Manufacturing)

2. FA Integrated Solution e-F@ctory

Solution for advanced factories of the future


Data collection technology

Data analysis technology

Data communication technology

Sensing Artificial intelligence

Simulation

High-speed communication

Device-to-device communication Efficient collection

The following shows evolutions of the ICT and information infrastructure.

"Monozukuri(Manufacturing)" according to Environmental Changes


"Monozukuri(Manufacturing) " using Digital Space

Product development

/Design

Trial /Evaluation

Production /Test

Packing /Shipment

Process in factory

Analysis

Market info.

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

・3D printer ・Evaluation data accumulation ・Failure analysis /feedback

・3D design ・Virtual reality ・Reliability prediction ・Simulation evaluation ・Machinability evaluation

・Automation ・Monitoring ・Quality analysis/feedback ・Equipment preventive maintenance ・Consumption energy management

・Automatic packing/shipment ・Delivery planning ・Individual identification ・Traceability

Using Digital spaces, each process work efficiency and shorten term.

・Market info. collection ・Trend prediction

Digital space


Digital space shortens distance to the ideal but cannot give perfect solution.

Only "humans" can fill gaps between reality and virtual space. Only "humans" can improve higher quality. Only "humans" can find improvements.

Only "humans" can "realize" design data simulated on digital space. "Humans" suitably use things optimized in digital space to optimize "Monozukuri(Manufacturing)".

Digital space Real

Next-generation "Monozukuri(Manufacturing)“ that "Humans" realized with Machines

Realize design data and adjust/improve

Supplies the optimal data created in digital space to robot systems/humans.

Feeds back unpredictable "awareness/experience/know-how".

(On-site knowledge)


1. Future Vision of Monozukuri (Manufacturing)

2. FA Integrated Solution e-F@ctory

A solution for advanced factories of the future


The major concept is “TCO*" across development/ manufacturing/maintenance. This solution optimizes factories using advanced technologies/information to support the future of Monozukuri(Manufacturing).

• 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

- FA integrated solution -

Basic concept

<Production site optimized by >

Mitsubishi's Efforts

*TCO：Total Cost of Ownership


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.


Controller products

Drive products

Energy -saving products

Mechatronics products

ERP

CAD

SCM

SCADA CAM

Simulator

Production site

FA-ICT interface

ICT system

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

Collecting real-time info. on manufacturing sites

Feedback FA-ICT info. interface products

FA-ICT linkage


Necessary Elements for

Need methods for figuring out what is happening at

production sites promptly, correctly, and efficiently

Need methods for linking various PLM tools


ＥＺＳｏｃｋｅｔ

CSP+

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 Engineering tool CAM


, high-speed/large-capacity communication

Packing process

Control info. (network shared memory)

Production instruction, manufacturing/quality

info. (massage communication)

= Message communication

(transient communication) = Access to shared memory

Even a large amount of quality/manufacturing info., it will not affect transmission of

control info.

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.

FA Network Connecting Lines, Equipment, and Devices

Control/production/quality info. at production sites can be "visualized", and analysis will be easy.

Bottling process


Device level CC-Link AnyWire ASLINK CC-Link Safety

I/O control Safety control Motion control

SSCNET

Controller distributed control

CC-Link IE Field

Info. communication

CC-Link IE Control

Ethernet Computer level

Controller level

Seamless info. linkage

SLMP SLMP (SeamLess Message Protocol): Common protocol that provides seamless device communication regardless of network types/hierarchies


Database, ORACLE, SQL Server, etc.

ICT Linkage Technology

Various applications can be operated in the ICT system, such as ERP, MES, schedulers, and simulators.

ERP CAD SCM SCADA CAM Simulator

ERP

CAD

SCM

SCADA

CAM

Simulator

Adoption of this architecture is postponed because of the expandability and versatility.

MES

MES

Direct connection Network fault processing : Buffer memory : Automatic refresh Automatic setting of

collection time info.


Information Interface Products

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.

Production and inspection information of production sites can be collected in real time.

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.

To the system that has already operated and is operating, this module can be additionally installed, allowing data collection of the system.

MELSEC-Q PLC MES Interface MES Interface IT for MELSEC-Q PLCs GOT2000/1000 HMI MES Interface

BOX data logger High-speed Data Logger Module for MELSEC-Q PLCs Data collection analyzer MELQIC MES Interface

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).


Partners having abundant experience/technologies in various fields

e-F@ctory Alliance Mitsubishi Partners to be familiar with problems offer the best solutions.

Offer software required for collection/analysis/management.

Offer devices required for measurement/control.

Total Support for the construction/operation on production-site

SI partners Software partners

Device partners

No. of participants: 282 companies (including both inside/outside Japan) (as of Feb.2014)


Design phase

Maintenance phase Production phase

Utilize CAD for machine simulation : Interference check : Operation verification

Utilize schedule system for production planning : Best approach for production planning

Utilize data logging : Implementation of traceability : Troubleshooting quickly

e-F@ctory : Production efficiency by using digital space in the phase of design, production and maintenance

Digital space

“Digital space” will be used more and more for Monozukuri (Manufacturing)

Solution by utilizing ICT


①EPLAN supports Mitsubishi FA products information Easy to check : Line connection, interference Easy to calculation : Line length

EPLAN（Software Partners) EPLAN Data Portal Electrical CAD drawing

②Support of label exchange between EPLAN and iQ Works (Development:2015-2016) Advance : Design efficiency, Quality

EPLAN iQ Works （GX Works3）

Signal name can be exchanged between EPLAN and iQ Works

Electrical CAD

drawing iQ Works

system configuration

③Auto generation of system configuration (I/O assignment, Network Parameter) in iQ Works Advance : Design efficiency for utilize of Electrical CAD drawing

Mitsubishi FA

Products macro

Import macro data


e-F@ctory concept release 2003

2000

2003

2005 MES Interface module

2006 GOT-MES

C Controller 2007

2008 MES Interface IT

2006

2008

2011 2014

Model plant

[2005] Nagoya [2010] Fukuyama [2012] Kani [2013] Gunma [2013] Changshu, China

History of


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.


Integrated analysis/ optimal management/ Remote diagnosis

IoT/Big Data Compatibility, Architecture of

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.

The best data-processing architecture is the e-F@ctory, in which primary data processing is conducted at production sites.

The keyword is ...

Local analysis/optimal production Quality management


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 Data analysis software (Revolution Analytics product)

Process data measurement/monitoring (CIMSNIPER produced by NIPPON DENNO) Primary data processing

Instruction

Instruction

Various sensor data

Instruction + Sensor data

Application Example (Preventive Maintenance System for Production Equipment)

http://www.mitsubishielectric.co.jp/news/2014/0929.pdf


Necessary information can be Accessible from Anywhere Anytime

Allow remote monitoring about operating status of equipment and instructions to the maintenance workers.

Smartphone Tablet PC

Future Prospects


Proactive Predictive

Reactive

Equipment Data Collection/Analysis on the Real-time

Production efficiency(JIT) will be realized through real-time collection/analysis on production/energy data.

Future Prospects


Company and production activities link seamlessly to respond to market/situation changes.

Improve the company value by improving productivity/quality/product value and conducting social contribution through energy saving.

Shift from Production Phases to Entire Industry

Future Prospects


We will widen the scope of e-F@ctory and enhance the functions with our partners.

for Promoting "Monozukuri(Manufacturing)"

We evolve e-F@ctory with accumulated know-how for the "Monozukuri(Manufacturing)" future.

future manufacturing and fa integrated solution...

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