LITOSTROJ POWER STATE OF THE ART Background, field of expertise, - - PowerPoint PPT Presentation

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LITOSTROJ POWER STATE OF THE ART Background, field of expertise, - - PowerPoint PPT Presentation

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PROJEKT: E! 4177 PRO-FACTORY UES Ubiquitous oriented embedded systems for globally distributed factories of manufacturing enterprises 1.7.2008-31.6.2011 LITOSTROJ POWER STATE OF THE ART Background, field of expertise, activities within

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PROJEKT: E! 4177 PRO-FACTORY UES Ubiquitous oriented embedded systems for globally distributed factories of manufacturing enterprises 1.7.2008-31.6.2011

LITOSTROJ POWER – STATE OF THE ART Background, field of expertise, activities within project

Boža Pustovrh Martinčič & Borut Rihtaršič

LITOSTROJ E.I., Ljubljana Kick-off-meeting Gijon, 13th November 2008

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E! 4177 PRO-FACTORY UES

Contents:

  • Introducing
  • Background
  • Field of expertise
  • Activities within project
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EUREKA EXPIRIENCE

  • E! 1156 INTO ISYTRANS Development And Integral Structuring Of

Technology, Methods Of Organization, Man And The Environment For Implementation Of Organization Concepts Management Structures In The Field Of European Railroad Track Vehicle

  • Construction. (1992-1994)
  • E! 2404 Eureka-Factory EURAS Market oriented flexible assembly

processes, Germany, Hungary, Sweden, Slovenia, (2000-2001)

  • E! 2612 Eureka-Factory COSAP: Customer -oriented design of on-

site assembly processes, Germany, Hungary, Sweden, Slovenia, (2001-2004)

  • E! 2736 Eureka-Factory TRUST: Use of Regional Potentials With

Respect To Problem-Solving Processes in Production Germany, Italy, Slovenia, (2002-2004)

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BACKGROUND AND MOTIVATION

Manufacturing issues

  • One of the most important characteristics of the modern

manufacturing and fabrication business is its complexity and non determinism (inputs are non-deterministic, system is unstable, environment is unpredictable).

  • Project management and order development in modern network
  • rganisation are preformed in distributed environment.
  • In dynamically changing environment, important requirement for

effective management and control of a workshop is efficient and accurate monitoring of production, decentralized decision making and an efficient co-ordination of autonomous interacting entities.

  • The basic problem is that we deal with inaccurate production data,

which leads to inaccurate reporting and consequently poor non-

  • ptimal decisions.
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BACKGROUND AND MOTIVATION

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OBJECTIVES

  • to build an autonomous system for decision making shop floor control,
  • designed in such a way that different types of users can address

different levels of information,

  • accessible anytime from anywhere,
  • access for different type of Log-in users,
  • data and access security,
  • fully integrated solution (ERP, CAD, CAPP,…),
  • easy navigation,
  • no extra software needed (only web browser),
  • build on and with the latest programming technologies and tools (.NET

technology).

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PROJECTS LEADING

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OBJECTIVES

Project managing Department managing Function managing Function managing Function realization

Multiproject coordination

[looking for global solution]

Enterprise leading

Company Management Level Department Management Level Operational & Resource Management Level IN OUT

Function realization

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CURRENT SITUATION in IT & GAP

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IT MODEL of PRODUCTION COMPANY

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WORKSHOP MODEL

(functional view)

SCHEDULING DISPATCHING PREPARATION

HIGHER LEVEL PLANNED WORK ORDERS DOCUMENTATION MATERIAL WORK ORDER IN PROCESSING

OPEARATION DETAILING

TOOLS WORK PLACE (RESOURCES) PROJECT COORDINATION DOCUMENTATION INSTRUCTIONS OPERATION STATES WORK PIECE SYSTEM BDE / MDE / CAQ

WORKSHOP

OPERATION STATES

OPERATION

MICRO PLANNER WORK MANAGER PLANT MANAGER WORK MANAGER PREPARATOR OPERATOR

PLANT CONTROL SYSTEM

CONTROL COORINATION PLAN

WORKSHOP CONTROL

MICRO PLANNER

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WORKSHOP MODEL

(functional view)

SCHEDULING DISPATCHING PREPARATION

HIGHER LEVEL PLANNED WORK ORDERS DOCUMENTATION MATERIAL WORK ORDER IN PROCESSING

OPEARATION DETAILING

TOOLS WORK PLACE (RESOURCES) PROJECT COORDINATION DOCUMENTATION INSTRUCTIONS OPERATION STATES WORK PIECE SYSTEM BDE / MDE / CAQ

WORKSHOP

OPERATION STATES

OPERATION

MICRO PLANNER WORK MANAGER PLANT MANAGER WORK MANAGER PREPARATOR OPERATOR

PLANT CONTROL SYSTEM

CONTROL COORINATION PLAN

WORKSHOP CONTROL

MICRO PLANNER

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BASIC ELEMENTS OF IMPLEMENTATION

  • Web technologies: ASP.NET (Active Server Pages) as programming

environment, C# as primary programming language.

  • Relational Database Management Systems (RDBMS): SQL Server

2005 on Windows Server 2003, T-SQL language for data retrieval.

  • Visual Studio 2005.NET Professional edition for web application

development & Touch Panel PC desktop application.

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DIFFERENT TYPS OF PRODUCTION COMPANIES

  • ETO – engineering to order (welding, machining, assembly)
  • ATO – assembly to order
  • MTO – manufacturing to order
  • MTS – manufacturing to stock
  • Develop for each type is needed.
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OPPORTUNITIES

1. Production of welding parts process 2. Delivery, transport and build in process 3. Logistics in assembly department: preparing assembly parts, warehousing and internal transport 4. Development documentation in workshop: tracing, changing control CHALLENGES: planning & controlling, transability, quality, tracking & tracing

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WELDING PARTS PRODUCTION PROCESS

  • A lot of different products at the same time
  • Big dimensions (to 5 m and more)
  • Each product is made of a lot of welding parts (sometimes over

100)

  • Information are very important:

– More than 5000 operations per month (to plan & control) – About 10.000 different documents every month (working orders, transport documents, drawings, sketches, heat treatment charts, welding book,…)

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WELDING PARTS PRODUCTION PROCESS - Motivation

  • A need for advanced control of process (exacting piece of work to
  • rder)
  • No appropriate products on the market for support information flow

in ETO production

  • Development of theoretical concepts on production cybernetics

(definition of EWS, collaboration work concepts in distributed environment)

  • Development on information communication technology (net

technology, VPN, RFID feelers,…)

  • Good experience with our system (shop floor support by net

technology)

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WELDING PARTS PRODUCTION PROCESS - Need

To develop a system, which offers:

  • Prepared input information about technological procedures and

production planning data

  • Support by planning and scheduling
  • Collecting data about tasks, work equipment and work systems

statuses, process parameters and product quality characteristics

  • Production situation evaluation and its characterization with

performance indicators

  • Making decision on authentic (reliable, trusty), up-to-date

information and on prepared scenarios for standard procedures (work and typical problems)

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WELDING PARTS PRODUCTION PROCESS - Request

  • More than one worker at the working place
  • Tracking the worker, who works at different places during the

working day

  • Exacting planning process (welding and machining change during

production)

  • Traceability:

– Who worked on the specific product – Welding parts (from cutting to – Process parameters (electric current, voltage, welding velocity,…) – Quality control data (penetrant fluid inspection, ultrasound inspection, visual control,…)

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UBIQUITOUS SPACE FOR SHOP FLOOR MATERIALS TRACKING SYSTEM

  • The most relevant static information a smart item can hold and

reveal is its identifier. Identifiers or names can be used to uniquely distinguish between single items of the same type of object.

  • Design of ubiquitous space involve using of ubiquitous device

network of embedded systems which provides real time data interface over a wide range of tiny microprocessors, wireless sensors (Xbee(Zigbee)), RFID tags etc.

  • This approach add more awareness to design of ubiquitous space.

This awareness means that the network can detect and respond to the environment, often without any human interaction.

  • These autonomous networks are very scalable and flexible, allowing

self-discovery of new nodes and can cover large areas without the need for extensive fixed infrastructure. Sensor networks can be deployed very quickly and can use web services to integrate with

  • ther IT systems.
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UBIQUITOUS SPACE FOR SHOP FLOOR MATERIALS TRACKING SYSTEM

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Zahvala / Acknowledgement of Support

To delo je deloma sofinanciralo Ministrstvo za visoko šolstvo, znanost in tehnologijo RS (št. pogodbe: 3211-08-000205 in 3211-08- 000206). This work has been partially financed by Ministry of Higher Education, Science and Technology of RS (Contract No.: 3211-08-000205 and 3211-08-000206).

Hvala za pozornost / Thank You for the Attention