Manufacturing Technology Platform(MTP) Meeting
Zurich, Switzerland
SaaS-Based MES/MOM using
Wireless Sensor Network
Monday, 27 April 2009
S. K. Cha,
Cofounder & Strategic planning
ACS Co., Ltd.
skcha@acs.co.kr
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MES: Manufacturing Execution System MOM: Manufacturing Operation Management
Agenda
I. Who is ACS ?
II. Needs and issues for Mfg. IT
III.Core Technologies and features
IV. Summary
2
I. Who is ACS?
 Established in August 30, 1988 (20th anniversary)
 Located in Seoul, Korea – Manufacturing contry (45.2% of GDP in 2006)
 Concentrating manufacturing software solution – u-Manufacturing (uMfg® & Dabom®-Visualzier)
 Visulizer has successfully completed in HMC, POSCO including more than 520 project
 Announced iVisualizer & iTPM for SME in FY2002 and currently more than 120 references
 ACS solution at Romania, Poland, Slovakia, Singapore, Thailand, China & Japan
 ACS Facts
 Capital : USD 1.4 Million
 Annual revenue: USD 13M(2007), USD 15M(2008)
 No of employees : 62
 R&D: 5.2% of Revenue in 2008
 Main Business
 Consulting services for Manufacturing IT
 Visualizer – MES/MOM for global manufacturing
 iVisualizer – MES/MOM for SMEs
 iTPM – EAM for SMEs
 iDCU – M2M solutions
Series
Solutions
Manufacturing Processes
 Core Technology
 u-Mfg® middleware (iVisualizer) - (NeT, NeP, World Class Product, ES-ISO12119 certification)
 Lean Mfg. - 4 Zero (Waiting time, Inventory, Defects & Down-time) approach - (Patent No: 10-0545737)
 IT: Internet, mobile, RFID/USN, SOA with Web Services application - (Patents No:10-0695533 & 10-0788009)
 4M Auto-Configuration® - (Patents No:10-2008-0084699)
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I. Who is ACS?
 ACS solution in Auto & Steel industries
Hyundai Motor Co.
- More than 150 project has been completed
- Strong in MES for engine application
- Good reference for ALC (Assembly Line Control) system
POSCO
- Real time communication & large scale system
- Approach an emerging new technology
(Open UNIX System replaced from Special
designed process computer )
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II. Needs & issues for Mfg. IT
 Changing the Mfg. & IT environment
- Rapidly expanding global logistics and production requirements
- Hard to managing multiple plant in worldwide
- Increasing needed central managing high capital intensive
production equipment
- Increasing ICT maintenanace load and development risks
- Emerging Manufacturing 2.0 solution for global coodination
Manufacturing SOA: Operations process management,
User-centric interface, Mobile and wireless sensor
Source: u-Mfg Lab at POSTech
Source: AMR Research
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II. Needs & issues for Mfg. IT
 4M Integration in real time
- Mfg. Enterprises needed integration of 4M (Man, Machine, Material & Method) in real time for 4 Zero (Zero Waiting time, Inventory,
Defect, Down time) approach as lean manufacturing
- You cannot manage what you cannot measure – RTE (Real Time Enterprise)
change
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II. Needs & issues for Mfg. IT
 Major issues for develoment of u-Manufactuirng
- Fusion of multiple technologies are key for successfully implementation and generation of new business opportunity
Automated
Machines
Technology
Real-time interface
Data base
SOA, Web service
Network (e-Biz , Web2.0)
Ubiquitous Technology
RFID/USN
Manufacturing 2.0
Information
Technology
u-Manufacturing
solutions
Lean Manufacturing
6 Sigma, TQM
5S, TPM, OEE
JIT, TPS
SCM, APS
Consulting
Technology
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Machine Center (CNC)
Material logistic system
Robot
Machine Vision
FMS
Stack crane
Production
Technology
II. Needs & issues for Mfg. IT
 The wireless technogy
▶“CBM Is the Next Killer App For Wireless” – Dr. Jay Lee, Fortune Magazine, July 2002
- The Economist, 2008: A 14-page special report on the coming wirless revolution
- Intech magazine, 2009: Wireless is most adopt over the next five years.
- Design Integration: expanding broad application area focused on low cost
Real time device integration
Design Interation
External
Devices
Board Level
Embedded
Level
Chip Level
• M2M (Machine to Machine) Devices
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II. Needs & issues for Mfg. IT
 SaaS model
Software as a Service (SaaS, typically pronounced 'sass') is a model of software deployment whereby a provider licenses an application to
customers for use as a service on demand. SaaS software vendors may host the application on their own web-servers or download the application to
the consumer device, disabling it after use or after the on-demand contract expires. The on-demand function may be handled internally to share
licenses within a firm or by a third-party application service provider (ASP) sharing licenses between firms.
Ad-hoc/Custom
(ASP Model)
Configurable
(Single intant, option)
IT Trend
Configurable Multi-tenant
(metadata, security, authorization)
Configurable Multi-tenant scalable
(N:M connection)
SaaS Level
Source: Salesforce.com
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Source: Gartner Group
III. Core technolgies & features
 u-Manufacturing Model for SaaS model
• Multiple manufacturing IT layers goes simple layers
• Separate IT layer between real time and batch process
• Needs central managing for distributed multiple plant in real time (RTE: Real Time Enterprise)
Prospect of Manufacturing Application
Configuration of u-Manufacturing system
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III. Core technolgies & features
 Paradigm shift of development background
▶Distributed Architecture for Reconifigurable Manufacturing System & Single instance application at central IDC
- MES/MOM are real time infrastrature IT layer of manufacturng enterprises
- Open embedded system of low power comsuption in everywhere for green IT
- single instance application of central management for Green IDC
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III. Core technolgies & features
 4M Integration in real time for SaaS model
• Direct communication to device controllers via OPC, TCP/IP, MIMOSA
• Indirect communication to Process or sensor I/O by M2M device
• Wireless sensor communciation for tag management
• Manual data handling by touch screen, bar code reder & mobile devices
• SOA ESB provides common framework for interoperability to other enterprise application
MESA-11
ISA S95
ISO TC184 SC5
Open O&M
OAGIS
MIMOSA
OMAC
IEEE802.11.x
IEEE 802.15.4
6LowPan
ISO/IEC JTC1
IEEE1451
Standard sensor
Interface
International
Standard
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III. Core technolgies & features
 4M Integration in real time by M2M devices
• Wired M2M device
- Open embedded Linux based low power consumption intelligent device
• Wireless M2M device
- Low power and small size of IP based wireless sensor network
Wireless M2M node generates XML data for sever
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III. Core technolgies & features
 4 M Digitalization – manual data handling (Touch Screen & Mobile)
• Touch screen WBT (Windows Based Terminal)
• Managing for moving and multiple equipment
-
- Work order & report by mobile for production and maintenance
IT rosource in servers, no IT resouce in terminal as just plug & play
Low power comsumption, good for harsh environment
No issue of hacking and IT security
Easy to manual data entry by workers – display big characters & touch
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III. Core technolgies & features
 Comparation with other technology
Items
PLC/DCS
DAS
System configuration
Private PLC CPU and
network
(An Example : AB, Siemens
& Mitsubishi PLC)
Indepent serial
communication port with
PC (An Example: RIC,
MOXA)
Embedded DAS with PC
(An Example: Field bus)
Support Wired/wireless +
internet + existing
interface
Manual data handling
Operation
environment
Must needs PC for
management
Must needs PC for
management
PC based OS – Windows
NT
Open emedded Linux
International
standard
N/A – De Fecto Standard by
vendors
Recommended Standard
(An Example: RS-232C,
RS-422A, etc.)
OMAC
Focus on new ICT
standard
(MIMOSA, OPC, ISO,
IEEE, OMGi,
XML/HTML, WSDL,
SOAP…)
Cost
Middle
Low
High
Low
Application area
Sequencer control
Compete with PLC &
DCS Challenge to real
time coverage, stablility &
realibility
CNC and PLC
replacement
All area
(Zigbee, PLC, IP-USN,
WiFi, WCDMA, Wibro
and etc.)
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PC based Control
M2M
Device
III. Core technolgies & features
 Middleware Configuration for SaaS
L3
L1
L2
Auto-Configuration
L0
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III. Core technolgies & features
 Auto-Configuration
• Auto configuration for 4M resources
- Definiton funciton
- Editing function
- Tag mapping fuction
- Dynamic mapping function
After
Before
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III. Core technolgies & features
 Major middleware functions
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III. Core technolgies & features
 Predictable Maintenance
X = 48.4219 – 1.9485Tx + 0.9847Ty + 0.0857Tz – 1.0687T
Y = 159.2867 – 4.6858Tx + 7.7245Ty – 8.6694Tz + 0.5468T
Z = 175.4714 – 7.4281Tx – 5.4342Ty + 8.7649Tz – 0.9827T
Changing predictable model
by predictable parameters
Real time conpensation based
on measuring temperature & Speed
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III. Core technolgies & features
 Features of middleware for wireless sensor network
• Wireless becomes the default choice in production area
• Interoperability with legacy system for protects investment in past
• Reconfigurable 4M of auto-configuration provides rapidly chance of buisness and production environment
Prospect of wireless
Configuration of gateway for SaaS
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III. Core technolgies & features
 8 Main Features for SaaS
1
Multi-Tenant,
Shared Systems
5
2
3
4
Various Integration
Flexibility
Trusted Reliability &
Performance
Democratization of
Enterprise Apps
Easy to Customize :
Metadata-Driven
Customization
6
Mash-Ups
7
Application
Exchanges
8
Multi-Device
Delivery
Source: Salesforce.com
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III. Core technolgies & features
 Manufacturing Application – Needs transformation SOA
• SOA for MES application fits distributed all type of manufacturing enterprises
- It provides single intant MES application service
ISA-95 & MESA-11 MES model & ISO TC184 SC5
standard model
Transformation SOA for MES application
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III. Core technolgies & features
 Customization for industry characteristics
Aero space
Ship building
Medical & Industry
Equipmement
Auto Part &
Electric
Electronics
Steel &
Chedmial
Simiconductor
Industry
Custom
Application
Industry template
Industry template
Industry template
Industry
Common
Template
L1
L2
Middleware
for Saas
Single instant
Standard Application
(ISA S-95
MESA-11)
Auto-Configuration
L0
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III. Core technolgies & features
 Operation of SaaS model
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IV. Summary
 Benefits of SaaS based MES/MOM using wirless sensor network
ㅁ View point of TCO (Total Cost Owenership)
15
30
Development
cost
55
Maintenance cost
15
Benefit
절감효과
Middleware for
development
Middleware for
maintenance road
70
< TCO >
Develop cost
15Maintenance cost
< Benefit with Middleware>
ㅁ View point of user
ㅁ View point of middleware
- No more pay for hardware, software,maintanance,
and upgrade… just pay for use as plug and play
- No risks and pay to implementation, provide best
practices application
- No risks and pay to consulting services
- No risks and pay to software maintenance and
upgade for comapy groth up and business
environment change
- No Needs cable by Reconfigurable 4M
– Auto Configurator & Point Manager
- Easy to disparate application
– DB Wizard Manager
- Unfied 4M data model
– Real time data manager
- Easy to generate UI
– Application Template Manager
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