accelerating smart manufacturing with connected …...accelerating smart manufacturing with...
TRANSCRIPT
Accelerating Smart Manufacturing with Connected Machine Services
從智慧機械到智慧製造
Deh Hui Chuan / Andy Li
Strategic Engagement & Industrial IoT
Azure IoT R&D
Myth# 1: Manufacturing plants are standardized and homogeneous…
Reality: There are many protocol and HW to deal with and there is no winner in this war…. In short, the Brownfield
No winner in the field bus/industrial
ethernet war!
Myth#2: We just need to focus on building our next future factory…. Why do we still need brownfield?
1960s - 1970s 1980s 1990s 2000s 2010s
1968
1978 1989 1993 2001
1982 19951973 2002 2009 2011
2006
2018
Reality: You invested in various protocols and HW/SW over time…
1940s-1960s: 1st- 3rd gen NC
1961: 1st robotic arm
by Unitec
1950s: 1st SCADA
appears to work
with telephone relay
system….
Myth#3: I just need an end to end vendor to help me out in my entire manufacturing value chain….
Raw materials
Manufacturing plant Engine transportation
Engine tracking
Machine processingMachine transportationProduction line Machine tracking
Machine assembly
Machine transportation
Microsoft Azure enables scale through IoT PaaS services
▪ Azure enables Top 10 automation companies to leverage secure-by-default Azure IoT PaaS and focus on value creation
▪ Azure partners with builder ecosystem to offer predictive maintenance solutions, bundled with machines
▪ Azure enables manufacturers to focus on process optimization through digital transformation
Automation Companies Machine Builders ManufacturersGateway and SI
• Azure leverages specialized solutions integration to focus on process optimization; connectivity specialist for OT/IT interoperability.
Reality: There will be an ecosystem of experts that comes together in support of your value chain…
The Top Automation Companies today run on Azure IoT…
Azure-Powers up most Industrial IoT Edge Gateways and Solutions in Market today…
Myth#4: Let’s build some dashboards, AI models and have my Connected Factory up & running today!
Connected
Factory as a
Service
Result
Digital
Feedback
Loops,
Method Calls
Adaptability
AI Models,
Machine
Learning
Predictions
Time-
Series/Historic
al Data,
Hierarchical
Data Modeling
Transparency
Telemetry
Dashboards
VisibilityConnectivityComputerization
Value
Time
Reality: 7 step journey in Digital Transformation, you can always leapfrog but have you solved Steps 1-2? (Connected Machine)
Connected
Factory as a
Service
Increased Business Value
Optimized processes
Result
7
Digital
Feedback
Loops,
Method Calls
Taking action
“Self-optimizing”
Adaptability
6
AI Models,
Machine
Learning
What will happen?
“Being prepared”
Predictions
5
Time-
Series/Historic
al Data,
Hierarchical
Data Modeling
Why is it happening?
“Understanding”
Transparency
4
Telemetry
Dashboards
What is happening?
“Seeing”
Visibility
3
How to Connect?
“Plugging in”
Connectivity
2
What Data?
“Defining Tags”
Computerization
1
Value
Time
Many are looking to go
through Steps 1 & 2
Connected
Machines first
First, it’s Connected Machines, then it’s Connected Factory
Azure IoT
ecosystem (to enable brownfield &
greenfield scenarios)
Azure IoT
platform and
services
Azure Data
Platform and
AI
Azure D365
and 3rd party
providers(SAP, etc.)
Connected
Factory as a
Service
Increased Business Value
Optimized processes
Result
7
Digital
Feedback
Loops,
Method Calls
Taking action
“Self-optimizing”
Adaptability
6
AI Models,
Machine
Learning
What will happen?
“Being prepared”
Predictions
5
Time-
Series/Historic
al Data,
Hierarchical
Data Modeling
Why is it happening?
“Understanding”
Transparency
4
Telemetry
Dashboards
What is happening?
“Seeing”
Visibility
3
How to Connect?
“Plugging in”
Connectivity
2
What Data?
“Defining Tags”
Computerization
1
Value
Time
Connectivity: Open,
Secure and Extensible
Standard – OPC UA
Edge Computing
OEE: Remote Monitoring,
Predictive Maintenance
Quality Control: AI for
Defect Inspection
MES/ERP Integration
Process Optimization
Adaptive AI for Mfg
ActionsThings Insights
… so let’s go back to that thing call Brownfield and let’s figure out how to standardize to OPC UA… but why?
VDMA released a Semantic Interoperability/ Companion Specs guidance to various industries
But you haven’t told me why standardize? Well…. What if everyone spoke different languages… how do you draw insights looking at different data models?
Connected
Factory as a
Service
Increased Business Value
Optimized processes
Result
7
Digital
Feedback
Loops,
Method Calls
Taking action
“Self-optimizing”
Adaptability
6
AI Models,
Machine
Learning
What will happen?
“Being prepared”
Predictions
5
Time-
Series/Historic
al Data,
Hierarchical
Data Modeling
Why is it happening?
“Understanding”
Transparency
4
Telemetry
Dashboards
What is happening?
“Seeing”
Visibility
3
How to Connect?
“Plugging in”
Connectivity
2
What Data?
“Defining Tags”
Computerization
1
Time
Insights
… and that is why Azure Industrial IoT is built for open-ness and interoperability.
Presentation & Business Connections
Websites, Mobile Services
Dynamics, Notification Hubs
Azure Edge Analytics,
Azure ML on Edge,
Azure Functions,
Azure Edge Runtime
Azure Edge Analytics,
Azure ML on Edge,
Azure Functions,
Azure Edge Runtime
Azure IoT Edge
On-Premises: Machine Interoperability Azure Cloud: Data Ingestion & Processing, Command & Control Azure Cloud: Presentation
Indu
stri
al D
evic
es(O
PC U
A S
erve
rs)
Hot Path Analytics:
Azure Stream Analytics, Azure Time Series Insights…
Azure IoT Hub
Connected Factory Solution Accelerator:
OEE, KPIs calculation
Alarms, Events & Telemetry based on OPC UA Information Model
Cloud-based Device Management
OPC Client using OPC UA .NET Standard stack
OPC Publisher Module
Firewall
Cold Path Analytics, ML, Functions & Storage:
Azure Machine Learning, Azure Data Lake, Azure CosmosDB Graph…
UA Client/Server
(UA Binary)
UA PubSub
(JSON over AMQP/MQTT)
Azure Edge Analytics,
Azure ML on Edge,
Azure Functions,
Azure Edge Runtime
Micro-Services: OPC Twin, OPC Vault
OPC Twin & Proxy Modules
UA Client/Server
(UA Binary)IoT Edge Methods/Properties
& UA Client/Server (UA Binary over MQTT)
Hard truths summarized: Industrial IoT is after all NOT Consumer IoT
Manufacturing
environment is
complex by nature
• Long life cycles to
modernize
machinery
• Isolated business
processes
• Security and liability
challenges
Integrations and
platform
• Machines cannot
easily be replaced
($$$)
• Must run for over
20 years or more…
Interoperable
• Must be
interoperable to
avoid vendor lock-in
Complex Ecosystem
• Require ecosystem
to optimize
automation
processes and
enable new
business models
Use case sharing
▪ Producer and distributor of specialized plastics
▪ Five production sites
▪ Each site has two to six extruders
Use Case
▪ Samples are analyzed for quality control,
every two hours
▪ Cost for one sample: €50
▪ Total cost per month (eight samples
per day per extruder, 20 extruders,
20 days per month):
€160,000
The Business Case
▪ “Classic approach“
• Buy expensive hardware
• Do everything on-premise
▪ Cloud centric approach
• Use cloud technologies
• Start small
• Grow if successful
Two Options
End-to-End Solution Overview
OPC UAOPC Classicbrownfield• Siemens• Rockwell• Mitsubishi• …
Process andmachine data Other applications and services
Azure IoT Suite Connected Factory• OEE• Analytics• …
• dataFEED OPC Suite• OPC Proxy (Azure IoT Edge) • OPC Publisher (Azure IoT Edge) • Windows 10 IoT Enterprise• HPE GL20
The Result
Customer CTO: ”We wouldn‘t have achieved this that easy and without big investments if we had done this on premise.“
Initial cost Millions vs 6 digit cost12 months vs 10 man days
What did we learn from the case above on why cloud?
Fast
Scalability
Financial
Flexibility
… but not just that, security is also the biggest reason why cloud
Security Availability
Data
SovereigntyLiability
Microsoft Azure enables scale through IoT PaaS services
▪ Azure enables Top 10 automation companies to leverage secure-by-default Azure IoT PaaS and focus on value creation
▪ Azure partners with builder ecosystem to offer predictive maintenance solutions, bundled with machines
▪ Azure enables manufacturers to focus on process optimization through digital transformation
Automation Companies Machine Builders ManufacturersGateway and SI
• Azure leverages specialized solutions integration to focus on process optimization; connectivity specialist for OT/IT interoperability.
Remember we said we will come back to this picture to look at the Machine Builder side of the story?
Why? Because over 40% of Asia’s manufacturing exports are derived from making parts & components (upstream)… all relying on machineries to make it happen!
… there is a whole lot that needs to work in these machines. And this is a use case we are working on…
Which will see a whole new Managed Service Model being applied, truly bringing the value from connected machines to connected factory.
Connected
Factory as a
Service
Increased Business Value
Optimized processes
Result
7
Digital
Feedback
Loops,
Method Calls
Taking action
“Self-optimizing”
Adaptability
6
AI Models,
Machine
Learning
What will happen?
“Being prepared”
Predictions
5
Time-
Series/Historic
al Data,
Hierarchical
Data Modeling
Why is it happening?
“Understanding”
Transparency
4
Telemetry
Dashboards
What is happening?
“Seeing”
Visibility
3
How to Connect?
“Plugging in”
Connectivity
2
What Data?
“Defining Tags”
Computerization
1
Time
Managed
Service
Model
工具機(CNC)智慧工廠服務化
CNC Controller
DAQ
VimoNet
CNC
Sensor : • Accelerometer• Ammeter • Thermometer• …
BNC
USB
RJ45
Ethernet
Pre-install Azure IoT Edge & VMX software • Support various commercial CNC controllers, PLC and
DAQ.• Move cloud analytics and custom workloads to device
securely. Such as data normalization, ML Model, OEE engine…
• Perform anomaly detection on the device itself and respond to emergencies as quickly as possible.Intelligent Machine Box
Azure Market Place
• For Customer• One simple place to discover all the
capabilities that can be deployed to an the edge device.
Azure IoT Hub & Edge• Seamless deployment of AI and advanced analytics from
cloud to the edge• Centralized configure, update and monitor from the cloud
• All the modules are certified for quality and scanned for security vulnerabilities.
• For Service Provider• Publicize and monetize your IP• Bill anyone using the module securely, automatically, and
without writing a bunch of sensitive billing logic.
工具機(CNC)智慧工廠服務化導入成本預估
CNC 雲端智慧製造Jerry Hsieh 謝尚亨
GM 總經理
CIMForce International 上博科技
Professional quality, definitely worth your trust.
Professional quality, definitely worth your trust.
CNC精銑(Bo面)CNC精銑(T面)EDM加工(T面)WE加工(T面)
傳統鐉(鉆) CNC粗銑(Bo面) CNC粗銑(T面) 熱處理備料
傳統研磨
鐵塊 零件
Professional quality, definitely worth your trust.
CNC機台
加工坐標
程 式
刀 具
裝 夾
機台通訊與監控
工件資訊
機台資訊
刀具資訊
治具資訊
•機台型號•加工程式格式•上傳的網路IP•機台監控
•工件裝夾要求•治具型號
•機內/機外校正•工件加工坐標原點補正值
•刀具/刀把型號•刀具安裝伸出長•刀具之ATC刀號
•加工程式版本•切削程式順序•程式對應刀號•冷卻指令
• IoT技術應用•加工資料與機台訊息上/下傳•主軸負載與電流監控
Professional quality, definitely worth your trust.
效率低LAN SERVER
CAM手動編程
手動上傳加工程式
加工任務通知
現場加工
人工發行圖面
生產管理 準備材料
手動下載加工程式至機台
易出錯
Professional quality, definitely worth your trust.
機台 零件
治具 刀具 材料
收費
CAPP/MES
FMSMULTITASKINGLATHEWEDMEDMCNC 量測
MONITORING (機台監控) 數據傳輸
量測程式
Auto-CAM
自動佈點
切削模擬
線割程式
雲端運算CAD/CAM
PLM/ERPAPS
INTERFACE
…
1. 加工資源共享媒介服務2. 機台監控
(INTRANET/INTERNET)3. 雲端運算4. 雲端數據儲存5. 資源數據共享平台
…
Professional quality, definitely worth your trust.
雲端資料庫
刀把資訊刀具資訊 捨棄式銑刀 捨棄式刀片金屬材質 加工條件
常用刀
雲端資料庫
Cloud
LOCAL
同步儲存
Hybrid
Adapter…
Adapter 切削模擬
Cloud
AutoCAM
Professional quality, definitely worth your trust.
雲端資料庫
同步儲存
Cloud
Hy
brid
機台規格參數機上量測測頭刀具測量
雲端資料庫
…
機台類型 控制器 MQL 回霧回收
LOCAL
機台編號管理
機台與治具底座配置
刀具管理主程式產生機台3D模型
Cloud
切削模擬Adapter
Adapter
Professional quality, definitely worth your trust.
雲端運算機台型號
CAM編程
機台資訊管理刀具資訊管理
數據更新 啟動CAM 打開模型 CAM編程 程式上傳 加工模擬 模擬確認
雲端存儲
治具資訊管理
LocalDB
根據規則篩選機台/治具/刀具
刀具/刀把/刀組數據治具數據/3D模型
•機台數據•後處理器
系統自動輸出之資料與數據• e工單資訊: 使用刀組/切削順序/…•檔案: CAM檔/裝夾圖&JT/模擬模型/…• POST之路徑加工程式/…
•模擬報告• 3D模擬動畫•優化之加工程式
Hybrid
Local
Cloud
機台+治具底座3D模型
•模擬模型•加工程式
模擬運算
Professional quality, definitely worth your trust.
來料接收 指派機台
加工任務管理刀具資訊管理
手動CNC加工
各機台虛擬刀具庫資訊•刀具編號/規格•刀具現存壽命
機台工件加工任務資訊
更新機台負載資訊
生管人員
加工任務導入
•工件加工任務資訊(件號/版次/數量/…)
雲端運算
雲端存儲
治具管理
加工任務管理
工件機外裝夾/校正
•治具型號與檢校有效期確認•治具狀態資訊更新
•工件RFID編碼•工件加工原點坐標補正值
工件上機 掛換刀
•工件件號•機台編號/IP
•選擇之機台加工坐標
更新實體機台刀具庫資訊:ATC刀號/刀組ID
產生主程式
主程式產生器運算
•機台編號/控制器型號•工件件號/程式版本•子程式名稱/切削順序•程式粗精銑性質•掛刀數量/程式對應刀號•刀具冷卻方式•刀具伸出長•選擇之機台加工坐標•工件加工原點坐標補正值• ...
加工主程式
程式上傳機台開始加工
•加工主程式•加工子程式
更新工件加工任務狀態資訊
Hybrid
Local
Cloud
Professional quality, definitely worth your trust.
Web API
Web API (Ajex)html (jsp)
Web API
Web API
MSMQ
Windows
Edge Computing
C#
ECS Sever
Web API
Identity ProvidersAuthorizations
Token,Jwt
Windows
Browser
Angular 5
Client
C#
CAD/CAM software
Client
Windows
Web API
API Gateway Server
Java
Windows
Spring Boot
SQL Database
Java
MES AP
MicroService
Windows
Spring Boot
Eureka
Machine B
Controller B
Machine A
Controller A
Background Application
Windows
C#
NX
NCS
ESPRIT
...
Task Manager
C#
Task Dispatching
Windows
file
Linux
Machining Program
Apache
FTP Server
3D Model
file
Professional quality, definitely worth your trust.
• 刀具管理• 治具管理• CAM編程管理• 加工模擬• 加工任務管理• MES
Microservices
VM
製造模組微服務
Browser CAM
機台控制模組(ECS)
IoT Edge
Professional quality, definitely worth your trust.
機台控制模組(ECS)
EdgeComputing IoT Edge
Optical Sensor
RFID
•儲位資訊•工件資訊
•工件搬運指令•夾爪更換指令
•加工程式傳送•即時狀態監控
ECS
ECS
•即時狀態回報•歷史狀態回報
•加工任務
狀態資訊
•加工任務資訊•工件資訊•設備狀態資訊• …
加工程式 加工程式
加工任務
CloudComputing
•自動編程•加工模擬• …
•加工任務導入•機台/刀具/治具資訊
•資訊看板-加工進度/機台狀態/稼動率/報警記錄/…
CloudLocal
Professional quality, definitely worth your trust.
FMS
CMM自動編程Auto
-CAM
CloudComputing
NCS加工模擬
CMM報告生成
資訊看板
Professional quality, definitely worth your trust.
系統產品方案定位考量
考慮資安問題,客戶希望系統建在內部
由單一模組開始導入再逐步增加功能!
單一功能模組居多(SERVER建置在雲端)
客戶數量佔比 <10% <=30% ~60%
商業模式方向 全模組銷售+維護費模組銷售或雲端(配合合作夥伴)
雲端服務、按機台每月收費
銷售策略 提供全模組及單一功能 先單模組、再整個系統 網路服務、租賃為主
伺服器 私有雲 可以使用混合雲或私有雲 使用公有雲
依不同客戶需求、提供不同商業模式與服務
私有雲 公有雲混和雲
外包服務
Professional quality, definitely worth your trust.
平台服務
雲端計算
技術情資
SOHO
廣告
中/小企業
中/小企業
中/小企業
中/小企業
中/小企業
中/小企業
集體採購
外包服務的機會
•外包作業困難
•品質不穩定
•交期無法控制
•價格差異大
電子商務(買/賣雙向服務)
中小企業
客戶
出售製造資源(產能)
購買設備/原物料/耗材/培訓/認證/人才資源/…
購買製造資源/原物料…
賣買SOHO客戶
設備廠商
精密機械零件廠商
出售刀具/治具/工具/耗材/…
•技術支持•外包管理• SOHO•教育訓練•認證•稽核服務• UBER服務•…
…
…
…
Partners & Microsoft come together for your Industrial IoT requirements as with the examples you saw earlier
VMs, VNet, KeyVault, Active Directory, Resource Manager, Azure Portal, …Globally Available Edge/Private/Public Cloud Infrastructure (IaaS)
IoT Edge, IoT Hub, Time Series Insights, CosmosDB, AzureML, …Scalable, Managed Services for Common Patterns (PaaS)
Connected Factory SA, OPC Publisher, OPC Proxy, OPC GDS, OPC Twin, …Scalable Services for Manufacturing Interoperability and Data Modeling
Services for Specific Use Cases
Applications that Solve Business ProblemsA
zure
Part
ner
From Connected Machines to Connected Factory –value add to all parties in the ecosystem
For Manufactures
• Productivity: counter labor
shortage
• Global Operation: efficient supply
chain management with better
data transparency and
integration.
• Mass Production vs Mass
Customization: Need to nimbler
to adjust production capacity.
• Risk Management: Data
governance and trade-war.
For Machine Builder
• Value-Added: Offer turn-key
solution to support whole
production line, not just a single
station
• Global services: Offer remote
consultant services to
international customers through
packaged solutions, carried by
cloud
For System Integrator
• Extend business to SMB, who are
usually lacking IT capacity to
manage on-prem servers and
customization.
• Extend footprint to global market,
to support cross-country business
and operation
• Scale their solution by leveraging
Azure data and advanced analytics
services without worrying about
operations.
• Accelerate their DevOps cycle by
leveraging IoT/AI assets on Azure,
no need to re-create the wheel.
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