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Manufacturing Webinar AMS

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Manufacturing Webinar AMS

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Manufacturing Webinar AMS

  1. 1. 2 Copyright Amorph Systems GmbH; confidential Introduction Frank Frauenhoffer Managing Director Development & Operations • Founder and Managing Director of Amorph Systems • Over 20 Years Experience in Automation and Vertical Integration • Worked in many Industries, e.g. Automotive, Electronics, Semiconductor, Photovoltaic, etc. • Leader of SMARTUNIFIER Product Development • Based in Stuttgart, Germany • Contact email: frank.frauenhoffer@amorphsys.com mobile: +49 151 51094525
  2. 2. 3 Copyright Amorph Systems GmbH; confidential Amorph Systems at a Glance Amorph Systems was founded with the clear vision to provide the best IT products & services for integration and operation of complex logistics systems. „Transform Data into Value!“ Key Business Domains are: Airport Solutions Industrial Solutions
  3. 3. 4 Copyright Amorph Systems GmbH; confidential AIRPORT SOLUTION: AMORPH.aero
  4. 4. 5 Copyright Amorph Systems GmbH; confidential INDUSTRY SOLUTION: SMARTUNIFIER File based (e.g. CSV, XML) Webservices / REST OPC-UA ISO/TCP SEMI SECS II and SEMI PV2 MQTT Beckhoff Siemens S7 ... File based (e.g. CSV, XML) Webservices / REST OPC-UA IBM MQ ActiveMQ MQTT SAP MII Database (SQL) ISO/TCP SEMI SECS II and SEMI PV2 AZURE AWS Mindsphere ... Equipment Devices Information Models Mappings Enterprise Context Simulation SMARTUNIFIER Channel 1 Protocol 1 Channel 2 Protocol 2 Channel 3 Protocol 3 Channel 4 Protocol 4 Channel 5 Protocol 5 Channel 6 Protocol 6 Channel 8 Protocol 8 SMARTUNIFIER BRINGS SEMANTICS TO DATA Dashboard Analytics Channel 7 Protocol 7 Automation Components
  5. 5. 6 Copyright Amorph Systems GmbH; confidential SMARTUNIFIER Unified IT Integration SIMPLE FAST POWERFUL
  6. 6. 7 Copyright Amorph Systems GmbH; confidential But how does Reality look like in Industry now? Anlage Up to Date Reality Example (Shopfloor) § Heterogeneous shopfloor equipment / factories § Non-standardized interfaces § Historical grown IT landscapes § Industry 4.0 requires a network where „every thing communicates with every thing“ (IIoT) – Need for interoperability これは材料I4711ですこれは現在 の製造が必要です。 ダイエットは 単なるテストです。した がって、それは本文に続くそれは とても美しいので、もう1つ書く 翻訳のためのさらなるテキストテ キストの終わり Это материал I4711который для текущегоТребуется производство. Diest - всего лишь тест.Поэтому в тексте он продолжаетсяПоскольку он настолько красив, мы пишем еще одиндополнительный текст для переводаКонец текста MES SCADA OEE Non-standardized Communication / No Semantic Data Lake interfaceA interfaceB interfaceC <?xml version="1.0" encoding="UTF-8"?> <Configuration status="info" monitorInterval="60"> <Properties> <Property name="log- path">log/Connector</Property> </Properties> <Properties> <Property name="lD">l4711/Property> </Properties> Это материал I4711который для текущегоТребуется производство. Diest - всего лишь тест.Поэтому в тексте он продолжаетсяПоскольку он настолько красив, мы пишем еще одиндополнительный текст для переводаКонец текста これは材料I4711ですこれは現在 の製造が必要です。 ダイエットは 単なるテストです。した がって、それは本文に続くそれは とても美しいので、もう1つ書く 翻訳のためのさらなるテキストテ キストの終わり Это материал I4711который для текущегоТребуе тся производство. Diest - всего Это материал I4711который для текущегоТребуе тся производство. Diest - всего これは材 がって、それは本文 に続くそれはとても 美しいので、もう1つ 書く翻訳のためのさ らなるテキストテキ ストの終わり
  7. 7. 8 Copyright Amorph Systems GmbH; confidential SMARTUNIFIER Integration Platform Flexible & Scalable: Parallel Connection of Multiple IT-Systems File based (e.g. CSV, XML) Webservices / REST OPC-UA ISO/TCP SEMI SECS II and SEMI PV2 MQTT Beckhoff Siemens S7 ... File based (e.g. CSV, XML) Webservices / REST OPC-UA IBM MQ ActiveMQ MQTT SAP MII Database (SQL) ISO/TCP SEMI SECS II and SEMI PV2 AZURE AWS Mindsphere ... Equipment Devices Information Models Mappings Enterprise Context Simulation SMARTUNIFIER Channel 1 Protocol 1 Channel 2 Protocol 2 Channel 3 Protocol 3 Channel 4 Protocol 4 Channel 5 Protocol 5 Channel 6 Protocol 6 Channel 8 Protocol 8 SMARTUNIFIER BRINGS SEMANTICS TO DATA Dashboard Analytics Channel 7 Protocol 7 Automation Components
  8. 8. 9 Copyright Amorph Systems GmbH; confidential SMARTUNIFIER Simple: Example of a Mapping • Triggers & Actions can be defined graphically (Drag&Drop) to transfer information from any source device to any destination device or IT System. • The used communication protocol (e.g. PLC, OPC-UA, file, DB, ...) for each communication channel is hidden. Connected to Native PLC Connected with OPC-UA
  9. 9. 10 Copyright Amorph Systems GmbH; confidential Operation of SMARTUNIFIER Integration Platform SMARTUNIFIER-Manager and Instances Runs in Data Center Runs on Industrial PCs Runs on SMARTUNIFIERBOX™ SMARTUNIFIER can be operated at the Edge, On-Premise, in Data Centers or in Cloud Platforms. Hybrid Deployments are supported as well. Possible Operation Types Runs in Platforms (SaaS, PaaS) Information Model Mapping Enterprise Context Simulation SMARTUNIFIER Examples
  10. 10. 11 Copyright Amorph Systems GmbH; confidential Operation of SMARTUNIFIER Integration Platform SMARTUNIFIER-Manager and Instances SmartUnifier SmartUnifier SMARTUNIFIER Instance SMARTUNIFIER Manager • Dashboard • Information Models • Mappings • Deployments • Communication Instances Information Model Mapping Enterprise Context Simulation SMARTUNIFIER Deployment Management Monitoring SMARTUNIFIER is based on a fully decentral system architecture (Swarm) using Container Technologies for virtually unlimited scalability.
  11. 11. 12 Copyright Amorph Systems GmbH; confidential Operation of SMARTUNIFIER Integration Platform Example: AWS Cloud Deployment Scenario SMARTUNIFIER Manager SmartUnifier Instance SmartUnifier Instance SmartUnifier Instance SmartUnifier Instance SmartUnifier Instance SMARTUNIFIER Instance SmartUnifier Instance SMARTUNIFIER Instance SmartUnifier Instance SMARTUNIFIER Instance SmartUnifier Instance SMARTUNIFIER Instance Protocol A1 Protocol A2 Protocol A3 Protocol ... Protocol E1..n Protocol E1..n Protocol E1..n Protocol E1..n Deployment View SMARTUNIFIER- BOX ... SmartUnifier Instance SmartUnifier Instance SmartUnifier Instance SmartUnifier Instance SmartUnifier Instance Equipment/ Device SmartUnifier Instance Equipment/ Device SmartUnifier Instance Equipment/ Device SmartUnifier Instance Equipment/ Device Services/App 1 e.g. MES Services/App 2 e.g. OEE Services/App 3 e.g. ERP Services/App … e.g. Analytics Repository ... AWS Cloud AWS Cloud AWS CloudAWS Cloud Data Center Data Center Industrial PC Data Center • SMARTUNIFIER can be deployed easily at the Edge, On-Premise as well as within the Cloud to accomodate to any possible communication requirement.
  12. 12. 13 Copyright Amorph Systems GmbH; confidential 5. Results Data Equipment 6. Process Data Equipment 7. Results Data Operator MES Equipment ID-Reader Operator Terminal 1. Read ID 2. Release Order 3. Start Order Processing 4. End of Order Processing 5. Send Equipment Results Data 6. Send Equipment Process Data 7. Send Operator Results Data Analytics 1. ID 1. ID 2. Release Order 3. Start Order 2. Release Order 3. Start Order 4. Finish Order 5. Results Data Equipment 4. Finish Order 6. Process Data Equipment 7. Results Data Operator 5. Results Data Equipment Protocol: OPC-UA or MQTT/JSON Protocol: ActiveMQ with XML Protocol: PLC via TCP-IP Protocol: Text via TCP/IP Protocol: REST/XML 7. Results Data Operator SMARTUNIFIER Informationsmodell Mapping Enterprise Context Simulation SMARTUNIFIER Operation of SMARTUNIFIER Integration Platform Practical: Implementation of Communication Workflows • SMARTUNIFIER is able to implement whole communication sequences, as these are required in real-world use case scenarios. • An Example Workflow (Car Assembly) encorporates the following steps:
  13. 13. 14 Copyright Amorph Systems GmbH; confidential SMARTUNIFIER Integration Platform System Requirements System Requirements • Computer and Processor 1 GHz or faster, x86-bit- or x64-bit-processor • Memory 512 MB RAM • Hard Disk / SSD 1 GB free space • Display PC (Engineering, Dashboard): 1280 x 1024 Resolution Mobile Devices (Dashboard): Apple iPhone 6 or higher, Android • Operating System Windows 10, Windows 8, Windows 7, Windows Server 2016, Windows Server 2012 R2, Windows Server 2012, Linux, MacOS For an optimal user experience always use the newest version of the operating system • Browser Current version of Microsoft Edge/Internet Explorer, Safari, Chrome, Firefox (further Browsers untested) • Other Docker Container Environment with its latest version • SMARTUNIFIER requires low hardware capacity only and can be operated on numerous standard hardware platforms.
  14. 14. SMARTUNIFIER Application Areas and Use Cases
  15. 15. 16 Copyright Amorph Systems GmbH; confidential SMARTUNIFIER Integration Platform Application Areas and Use Cases Communication Standards and Information Modelling • Migration to Industry Communication Standards (e.g. OPC_UA, MQTT, DDS, ...) • Migration to Information Semantics (Ontologies) Standards (e.g. EUROMAP, Automation ML, SECS...) Flexible Edge and Cloud Integration Digital Transformation Use Cases • Equipment Monitoring & Control • Edge Device Monitoring & Control • Sensor/Actor Monitoring & Control • Versatile Data Distribution (Edge, on-premise, Cloud) • Production IT Systems Integration (e.g. MES, ERP, OEE, ...) • Data Lake / Big Data Feeding • Production Heat Map • Condition Monitoring • Real-time Data Analytics • Predictive Maintenance • Equipment Self Service • Production as a Service • Machine Learning • Artifical Intelligence • ...and many more. SMARTUNIFIER provides seamless and easy to use Intercconnectivity for virtually all important Use Cases required to successfully perform Digital Transformation and migrate to Industry 4.0 • Southbound / Northbound Communication • Westbound / Eastbound Communication • Multi-Protocol and Multi-Channel Communication • State-of-the-Art Security <cloud/>
  16. 16. 17 Copyright Amorph Systems GmbH; confidential Mission: Stepwise Evolution SMARTUNIFIER leads to the Enterprise Nervous System EDGE Objects of an ENTERPRISE NERVOUS SYSTEM INDUSTRIAL RESOURCES Equipment (EQ) Sensors (S) Actors (A) Goods and Material (GM) Humans (H) APPLICATIONS On-premise (OP) Cloud (C) Edge (E) DATA STORAGES File System (FS) Databases (DB) Data Lakes (DL) 1st Stage: SU as Edge Integration Platform EQ A DB S S A EQ E ML App E AI App E Mon App F SU SU SU SU SU SU Edge GW Equipment Connector Device Connector Edge GW Edge GW OEM Connector H Operator Terminal / Smart Device GM GM SU Goods & Material Equipment Local File Storage SU SMARTUNIFIER Instance Traditional Communication Channel SMARTUNIFIER Communication Channel Supplier CLOUD C Predictive Maintenance App C Performance Dashboard App C Production as a Service App C Supplier App Public CLOUD C ERP Cloud App DL DB C Enterprise OEE App Data Lake DB Cluster C Artificial Intelligence App C Inventory Mgmt App FS File System Cluster IOT IOT ON-PREMISE / Outpost CLOUD SCADA App OP OP OP OP Dashboard App MES App ERP On-Premise App FS OP OEE App SU Supplier Gateway • 1st Stage: Starting with Edge Connectivity, step by step Devices and IT Systems are integrated seamlessly into ENS.
  17. 17. 18 Copyright Amorph Systems GmbH; confidential Mission: Stepwise Evolution SMARTUNIFIER leads to the Enterprise Nervous System Public CLOUD EDGE ON-PREMISE / Outpost CLOUD Objects of an ENTERPRISE NERVOUS SYSTEM INDUSTRIAL RESOURCES Equipment (EQ) Sensors (S) Actors (A) Goods and Material (GM) Humans (H) APPLICATIONS On-premise (OP) Cloud (C) Edge (E) DATA STORAGES File System (FS) Databases (DB) Data Lakes (DL) EQ A DB S S A EQ E ML App E AI App E Mon App F SU SU SU SU SU SU SCADA App OP OP C Equipment Connector Device Connector OP OEE App OP OP Dashboard App MES AppEdge GW SU SU Legacy Protocol Standard Protocol ERP Cloud App SU On Premise Gateway ERP On-Premise App DL DB FS C Enterprise OEE App OEM Connector SU Standard Protocol OEM Connector H Operator Terminal / Smart Device Data Lake DB Cluster SU C SU SU OEM Connector Supplier CLOUD SU Artificial Intelligence App Supplier Gateway C Supplier App C Predictive Maintenance App Supplier Gateway C Performance Dashboard App GM GM SU Goods & Material Equipment C SU Inventory Mgmt App FS File System Cluster Local File Storage SU • Long-term: All ENS Objects are interconnected and operate seamlessly with standardized Enterprise and Industry Semantics. IOT SU IOT SU OEM Connector C Production as a Service App SU SU OEM Connector Internet of Things SU SMARTUNIFIER Instance Traditional Communication Channel SMARTUNIFIER Communication Channel Long-term: SU as Enterprise Integration Platform Legacy Standard SU Supplier Gateway Edge GW Edge GW
  18. 18. SMARTUNIFIER Example Use Case with Splunk Information Model Mapping Enterprise Context Simulation SMARTUNIFIER • Seamless Interconnectivity • from Every Thing to Every Thing • at any Location (Edge, On-Premise, Cloud)
  19. 19. 20 Copyright Amorph Systems GmbH; confidential SMARTUNIFIER Example Use Case: Realtime OEE Monitoring & Analysis Challenges • Rapidly integrate production equipment and IOT devices (using simulated equipment) to upper level Manufacturing Execution Systems (simulated MES) and in parallel to Splunk Enterprise. • Realise convincing showcase with minimal effort and in shortest time frame. Business Statement • Realise an easy to use and convincing demonstrator for calculation and visualization of OEE Key Performance Indicators (KPIs) • The demonstrator addresses following areas: • Production Logistics: Visualization and analysis of fab-wide OEE • Quality: Correlation of quality problems with process parameters and plant events • Maintenance: Use of an OEE dashboard for maintenance (Augmented Reality) Approach with Smart Unifier • Apply Smart Unifier to integrate simulated production equipment with MES and Splunk • Create information models and mappings for connection to Splunk Enterprise (REST) and simulated MES (OPC-UA) • Map equipment data into structured JSON format for REST-based communication with Splunk Targets • Use of Splunk and SmartUnifier for data provision, examination, visualization and analysis • Overview of the possibilities for KPI monitoring and alarming (-> offline analysis -> automatic limit value monitoring -> machine learning) • Example for automated notification of other systems (e.g. MES) based on production data deviations • Example for advanced OEE dashboarding with mobile devices (Augmented Reality) OEE Analysis with Smart Unifier and Splunk Enterprise MES Model EquipmentToMes Mapping Equipment Model Splunk Model Channel M1 Channel S1 Channel E1 EquipmentToSplunk Mapping MES OPC-UA OPC-UA REST OEE
  20. 20. 21 Copyright Amorph Systems GmbH; confidential Line 1 Line 2 Line ... Line OEE Facility OEE Line OEE Line OEE Events: - Status Data - Results - Process Data OEE Production Scenario Overview Events: - Status Data - Results - Process Data Events: - Status Data - Results - Process Data Events: - Status Data - Results - Process Data Facility Model with multiple Production Lines and Equipment
  21. 21. 22 Copyright Amorph Systems GmbH; confidential MES Status Data Results Data Results Data Status Data 1 Status Data 2 Process Data 3 Process Data 1. Sending status data (events) from the system to Splunk 2. Sending results data (events) from the line to the MES and Splunk 3. Sending process data (high volume events) from the line to Splunk OEE-Dashboard OEE Production Scenario Information Flow Sending Status Data, Results Data and Process Data 2 1 2 31 Results Data
  22. 22. 23 Copyright Amorph Systems GmbH; confidential Overview of the quality history with emphasis on defective parts. Depending on the operating status, the corresponding status is displayed. Breakdown of the OEE by sub-components. Overview of the order history. OEE Production Scenario Dashboard and Analytics Example Splunk Enterprise Dashboard with Production Data Overview
  23. 23. 24 Copyright Amorph Systems GmbH; confidential Main Differences Comparison of traditional IT-Interface vs SMARTUNIFIER SMARTUNIFIERTraditional Interfaces / Middleware Complex register-based View to Device Data Comfortable Access to Device Data via configurable Information Models with Semantics Protocol Mapping from Edge Devices to upper-level IT Systems needs to be implemented manually Configurable Protocol Mapping from Devices to upper level IT Systems Limited Scalability and Performance / Typically outdated centralized System Architecture. Virtually unlimited Scalability / Fully decentralized / High Performance / Multiple Communication Channels No Data Semantics Full Support of Data Semantics Local Deployment of Interfaces or via central Middleware Local / Cloud / Hybrid Deployment of the Interfaces AWS Support / Splunk Support Not-reusable Interface Implementations for every single Device Type Fully reusable Interfaces for similar Device Types Traditional Middleware SMARTUNIFIER Multiple IT-Systems Multiple Devices/Equipment Historical – Database-Centric Bi-directional Communication Disruptive – Seamless Interconnectivity Fully Distributed – Unlimited Scalability Enabler of Digital Transformation Equipment Devices Information Models Mappings Enterprise Context Simulation SMARTUNIFIER Channel 1 Protocol 1 Channel 2 Protocol 2 Channel 3 Protocol 3 Channel 4 Protocol 4 Channel 5 Protocol 5 Channel 6 Protocol 6 Channel 8 Protocol 8 Dashboard Analytics Channel 7 Protocol 7 Automation Components
  24. 24. Q&A Amorph Systems GmbH Handwerkstrasse 29 70565 Stuttgart

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