Download - Towards the CYBER FACTORY versalog Colin Hales Agents Lab/Vic Fri April 26 2002 [email protected]
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““Towards the CYBER FACTORY”Towards the CYBER FACTORY”
versalog
Colin Hales
Agents Lab/VicAgents Lab/VicFri April 26 2002Fri April 26 2002
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versalogOverviewOverview
Evolution of automationEvolution of automation
Evolution of technology in factory automation Evolution of technology in factory automation
Economic and logistical imperatives driving change Economic and logistical imperatives driving change
Social - the role of humans in factories over the Social - the role of humans in factories over the years and in the future. years and in the future.
Holonics Holonics
Use of intelligent agents (max payback) in HolonicsUse of intelligent agents (max payback) in Holonics
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Manufacturing Paradigm Manufacturing Paradigm ShiftsShifts
1900 2000
CraftCraft
Sum of AllManufacturingtypes
1980s
Mass Mass ProductionProduction
Mass Mass ProductionProductionOptions ++Options ++
Mass Customisation
1910
Different philosophies for manufacturing are Different philosophies for manufacturing are neededneeded
mass-mass-customized, customized, low-volume, low-volume,
high-mixhigh-mix
mass-produced, mass-produced, high-volume, high-volume,
low-mixlow-mix
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versalog$$$$$$$$$$$$$$
Software & ServicesSoftware & Services Drive Total Automation Drive Total Automation Business for Process IndustriesBusiness for Process Industries
The worldwide market for Automation Products and The worldwide market for Automation Products and Services for Process Industries, over $44 billion in Services for Process Industries, over $44 billion in 2001, is expected to grow at the compounded annual 2001, is expected to grow at the compounded annual growth rate of just over 5% over the next five years. growth rate of just over 5% over the next five years. Without question, Without question, growth will be driven by growth will be driven by software and servicessoftware and services while traditional while traditional hardware-hardware-basedbased markets experience below average growth. markets experience below average growth.
Source:Source:
http://www.arcweb.com/arcweb/newsmag/auto55_autoproc.asp
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versalog- The Evolution of Control - The Evolution of Control
Technology-Technology-
108
109
107
106
105
104
102
101
100
103
1930 1940 1950 1960 1970 1980 1990 2000
FunctionalityIncreases
Solid State ControlRelay
PLC
Hierarchical PLC Structure
Distributed
HOLONIC
Granular H/W
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versalog- The Evolution of Control - The Evolution of Control
Technology-Technology-
EuphoriaEuphoria
Perception
Valley of Valley of CynicismCynicism
Gradual Gradual AdoptionAdoption
Americans…..
Australians
Time
FAD FAD STOPPERSTOPPER
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versalog
- - “When standing still is falling behind………………:”“When standing still is falling behind………………:” --Forces Driving ChangeForces Driving Change
• Change is by quantum leapChange is by quantum leap
• Competitive advantage through Competitive advantage through looking at your customer’s customer.looking at your customer’s customer.
• Machines that make the machines Machines that make the machines are automatedare automated
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State of TechnologyState of Technology
Imagine a world with 25 Bill Gates’Imagine a world with 25 Bill Gates’Supplier stranglehold gameSupplier stranglehold game
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versalog
State of TechnologyState of Technology
But it got better: Open SystemsBut it got better: Open SystemsLags PC world by a reducing timeLags PC world by a reducing time
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versalog
State of TechnologyState of Technology
Issues:Issues:
SensorsSensorsCommunicationsCommunicationsProgramming LanguagesProgramming LanguagesHMI/SCADAHMI/SCADAOperating SystemsOperating SystemsBUS standardsBUS standardsCPUCPU
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versalog
State of TechnologyState of Technology
Issues:Issues:
Stabilisation on open Stabilisation on open standards is occurring, standards is occurring, but the old but the old stranglehold persists stranglehold persists for political reasons. “I for political reasons. “I want 1 and 1 only BUM want 1 and 1 only BUM to KICK”.to KICK”.
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versalog
State of TechnologyState of Technology
Buying HabitsBuying Habits
The ONE STOP The ONE STOP SHOPSHOP
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versalog
State of TechnologyState of Technology
Highly ParallelHighly Parallel
The full circle….The full circle….
Centralised/Centralised/MonolithicMonolithicHighly serialHighly serial
De-CentralisedDe-CentralisedParallel/serialParallel/serial
GranularGranularParallelParallel
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versalog
- - “When standing still is falling behind………………:”“When standing still is falling behind………………:” --Forces Driving ChangeForces Driving Change
Technology/new materials.Technology/new materials.
GLOBALISATIONGLOBALISATION
Time to marketTime to market
Mass customisationMass customisation
Internet (Browsers/TCP/IP)Internet (Browsers/TCP/IP)
New semiconductor technologiesNew semiconductor technologies
Embedded WindowsEmbedded Windows
Microsoft active involvement – OPCMicrosoft active involvement – OPC
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- - “When standing still is falling behind………………:”“When standing still is falling behind………………:” --Forces Driving ChangeForces Driving Change
INTEGRATION of business systems and the plant floor INTEGRATION of business systems and the plant floor like never before.like never before.
Web Based implementations of traditional SCADAWeb Based implementations of traditional SCADA
WEB Based Industrial Devices/ProcessorsWEB Based Industrial Devices/Processors
COMMS: Foundation Fieldbus (finally)COMMS: Foundation Fieldbus (finally)
PROCESSORS: PC Based control (Windows CE)PROCESSORS: PC Based control (Windows CE)
““Granular Distributed Control Systems”Granular Distributed Control Systems”
DCS Functions on Traditional PLC/Soft PLCDCS Functions on Traditional PLC/Soft PLC
REGULATORY: The biological revolution….pharma/drugs REGULATORY: The biological revolution….pharma/drugs
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Traditional Manufacturing
Computing
Plant Floor
Admin
Engineering
Maintenance
OLD XYZ Co.OLD XYZ Co.Marketing/
Sales
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versalog
Holonics- 101Holonics- 101
Sub-contractor
HolarchyHolarchy
Sub Contract Dialogue
Sub-contractor
Sub-contractor
Subcontractor
Worker Worker
Task Assignments
HierarchyHierarchy
BOSS
Worker
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versalog
Holonics- 101 – in businessHolonics- 101 – in business
New XYZ Co.
Admin, Marketing,Sales, Engineering, Finance, Maintenance,
Plant Floor , Computing, Warehousing
New ABC CoEg outsourced
Computing.
.
New MNO CoEg outsourced Maint.
New PQR CoEg
Banking etc
Coetc Co
Customer CoCustomer Co
Team BasedTeam BasedEnd Customer Need FocussedEnd Customer Need FocussedProducer/Consumer NestedProducer/Consumer Nested
Time invariantTime invariant Space invariantSpace invariant
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versalog
Peoples Whole View of Business will change
It becomes, in the limit:It becomes, in the limit:
1)1) a set of managed material/service flows a set of managed material/service flows that ‘converge’ on a customer in that it that ‘converge’ on a customer in that it is ‘pulled’ into existence by demand.is ‘pulled’ into existence by demand.
2)2) A flow of money in the opposite A flow of money in the opposite direction.direction.
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versalog
Holonics- 101 – in businessHolonics- 101 – in business
Holonics is happening in business Holonics is happening in business practice, even though they don’t know it.practice, even though they don’t know it.
This is a useful indicator of imminence This is a useful indicator of imminence of readiness for Agentsof readiness for Agents
Automation systems driven by Automation systems driven by manufacturing demand as created ever manufacturing demand as created ever more directly by the customer base.more directly by the customer base.
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versalog
Agents in ManufacturingAgents in Manufacturing
Managing product life cycle in an environment of Managing product life cycle in an environment of continual changecontinual change Performance Monitoring and AnalysisPerformance Monitoring and AnalysisDecision supportDecision supportKnowledge ManagementKnowledge ManagementProcedure ManagementProcedure ManagementFault Detection and DiagnosisFault Detection and DiagnosisAlarm ManagementAlarm ManagementCondition Monitoring and Predictive MaintenanceCondition Monitoring and Predictive MaintenanceInventory ManagementInventory Management
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Agents in ManufacturingAgents in Manufacturing
Supply Chain ManagementSupply Chain ManagementTrainingTrainingERP/MES, SP95, SP81, SP88, IEC61139ERP/MES, SP95, SP81, SP88, IEC61139Scada setupScada setupCalibrationCalibrationQuality Information Systems Quality Information Systems Statistical Analysis Statistical Analysis Production Tracking Production Tracking Automated Data Management Automated Data Management Resource Management Resource Management Advanced Scheduling Advanced Scheduling
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versalog
Agents in ManufacturingAgents in Manufacturing
This is the fully holonic dream.This is the fully holonic dream.
Expert agents negotiate to run the plant optimally Expert agents negotiate to run the plant optimally according to orders. Humans intervene to make according to orders. Humans intervene to make critical decisions, teach, navigate change and get critical decisions, teach, navigate change and get involved in diagnostics and repair.involved in diagnostics and repair.
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versalog
Agents in ManufacturingAgents in ManufacturingSo what to do first?So what to do first?
First a little structure is neededFirst a little structure is needed
MRPMRP
MESMES
CellCell
MachineMachine
IncreasingIncreasingCost of Cost of ChangeChange
IncreasingIncreasingDemand Demand for for ChangeChange
Multi SiteMulti Site
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versalog
Agents in ManufacturingSo what to do first?So what to do first?
First a little structure is neededFirst a little structure is needed
MRPMRP
MESMES
CellCell
MachineMachine
My Interest is My Interest is herehere
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Agents in ManufacturingAgents in Manufacturing
Basic Agent Scope of WorksBasic Agent Scope of Works
Takes over ‘Auto’ control of plantTakes over ‘Auto’ control of plant
Learns how to run the plant. Humans teach it.Learns how to run the plant. Humans teach it.
Eliminate programming. Learn IEC61131, SP8Eliminate programming. Learn IEC61131, SP8
Diagnostics assistanceDiagnostics assistance
Deals with local production schedulingDeals with local production scheduling
Works with humans for manual operationsWorks with humans for manual operations
‘‘Inhabits’ plant, 24/7Inhabits’ plant, 24/7
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Agents in ManufacturingAgents in Manufacturing
Why is it possible….?Why is it possible….?
ONTOLOGIES require much less ONTOLOGIES require much less effort to formalise, they are highly effort to formalise, they are highly specified already although indirectly.specified already although indirectly.
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The Human FactorThe Human Factor
My observations:My observations:
Change is a shock in that it changes Change is a shock in that it changes the type of the work done the type of the work done andand the the number of people. Displacement number of people. Displacement occurs. It will be the same with occurs. It will be the same with Agents.Agents.
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What Colin Wants
Dumb HardwareDumb Hardware
Command Command Based SoftwareBased Software
Rule Based Rule Based SoftwareSoftware
Autonomy Co-Autonomy Co-operation operation IntelligenceIntelligence
Reasoning Reasoning SystemsSystems
Relay/I/O pointsRelay/I/O points
Programmable DevicesProgrammable Devices
Learning SystemsLearning Systems
Holonic ControlsHolonic Controls
Biological/”Life forms”Biological/”Life forms”CHCH
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The Cyber FactoryThe Cyber Factory
The manufacturing pyramid is run by The manufacturing pyramid is run by agents whose biological based agents whose biological based
Avatars call humans as needed.Avatars call humans as needed.
Of course, nano technology will Of course, nano technology will probably render it all obsolete, probably render it all obsolete, but……. I think there’s still a long way but……. I think there’s still a long way to go.to go.
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The Cyber FactoryThe Cyber Factory
That’s All, Folk.That’s All, Folk.
Thanks……..Thanks……..