ARC Forum in Pune India, 2011 1

ARC Forum in Pune India, 2011

Optimizing the Total Factory
Through Integrated Automation Solution
August 2, 2011
ARC Forum in Pune India, 2011 2
Contents
1. Issues in the manufacturing industry
What is the right approach?
2. Optimizing the total factory
What is the appropriate solution?
3. Application examples
Introduction of application examples
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Improvement of equipment operation cycle
Detailed operation analysis
Improvement of manufacturing quality
Collect, manage, and analyze quality information
Energy saving
Analyze energy consumption
Prompt response to changes in demand
Link status, performance, and planning
Growing need for traceability
Collect performance data and manage history data
Needs in the manufacturing industry
Needs informatization of the production floor
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Do you know your operation?
Data is needed to understand production status!
Planning
Step up operation

total optimization
Tooling change
22%
Shortage
10%
Running time
52%
Shutdown
4%
Startup
2%
Meeting
1%
etc
6%
Takt time
Upgrade

part
optimization
Trouble
2%
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Difficult to collect data from the production floor
Via media and networks
Operation process B Operation process C Inspection process Performance results input
Information Systems

Operating
instructions
Omissions and recording mistakes (wrong entry), inaccuracies due to mass entry, etc.
Extra work by manual operation
Delay in final processing
Delay in information transmission
due to inaccuracies
Operating
instructions
Performance
data input
Performance data
Production
planning system
Delivery
response
system
Operation process A

Operating
instruction
s

Operating
instruction
s

Operating
instructions
Performance management using
information systems
Before adopting IT
After adopting IT
Via network
Operation process B Operation process C Operation process A
Performance data
entry
Performance data
entry
Performance data
entry
Performance data
entry
Production site
terminal
Production site
terminal
Production site
terminal
Operating
instructions
Performance
data input
Operating
instructions
Performance
data input
Performance report directly from device
Collect detailed information that
cannot be extracted manually
Quick, accurate information
Detect not only the issue but also its
primary cause
Collected data are only the final results of the production process
There is no way to know the current status of the production line
(Human, Machine, Material)
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Collect information in real-time directly from the equipment
Easy-to-build system automatically gathers internal information
Significantly reduce setup and running costs for data collection system
Seamless communication between IA and IT
Product Linkage
Application Layer
(Manufacturing Execution System)


Business Layer
(Enterprise)
ERP/SCM
MES
Controller

Equipment
Control Layer
(Production Facilities)
I
n
f
o
r
m
a
t
i
o
n

L
i
n
k
a
g
e

Analysis
Result Control
Plan
Execute
Adjustment
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What kind of technology do you need
to solve these issues

Approach for optimizing the total factory
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Horizontal Integration
Vertical Integration
I
A
-
I
T

c
o
n
n
e
c
t
i
v
i
t
y

Integration of components
Need solutions to share and integrate information
Factory-wide optimization
IA-IT connectivity provides visibility of production and
controller information
Links different information layers
Seamless communication
among components
Linking products
throughout
manufacture
layers
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Feels like 1 System, 1 Engineering Tool
Common Controller Platform
Integrated Engineering
Tools
High speed transmission of control and synchronization
data among controllers
Share information among controllers and engineering tools
Reduce TCO(Cost reduction in design, maintenance, and application steps)
Achieve best performance possible
Communication
System
Design
Information
Integration
Programming

Monitoring
Data
Collection
Motion
PLC
Robot
CNC
PC
Embedded
System
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Intrinsic safety (guard management) and functional safe
The right safety components in the right places
Safety control through visualization of safety data
Requirements
for Factory
Safety
Total Safety
Solution
CC-Link Safety
connectivity
Total solution
(switch/sensor)
Safety Control
Lineup for different scales
Large
Middle
Small
Safety PLC
MELSEC-QS
Safety relays
CNC VFD
Servo
Seamless Network
Integration of Safety Control, Derives, and Devices
Safety Drives
Connectivity between
safety control and safety
drives
Safety Devices
Synergy with safety partners
Effective utilization
and visualization of
safety data
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Integrated & Open Network Structure
Computer
level network
Controller
level network
Device
level network
Data
capacity
Large
Small
Real time
performance
Low
High
Seamless
data
communication
Information
communication
Distributed control
I/O control Motion control
Seamlessly transmit control information throughout the system
MELSECNET/H
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Perform functions on the shop floor
Collect information according to situations or status on the
shop floor
Send out data from the shop floor in real-time
Detect changes
Reduce stress
Programless
High Reliability

Resolve
performance, cost,
and reliability
problems
Collect data
Automation
system
Information system
Embedded
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Shop floor
PLC controls the equipment.
PLC and information systems are
connected through a Gateway PC.
Easy &
no program! Direct
Real-time
Highly Reliable
Gateway PC
Embedded
system
Input the product
result data manually
Extra work by manual inputs
Incorrect & delayed Information
Limited information
Gateway PC
Need to develop
communication software
Difficult to achieve real time
data collection
Low reliability
High maintenance cost
OS version up, etc.
Wrong data
IT systems MES
ERP
Lack of data
Shop floor Shop floor
Operating
Instruction
&
Results input
Paper-Based
PC-Based Controller-Based
Paper-Based
IT systems MES
ERP
IT systems MES
ERP
Simple, easy, reliable and in real-time !
Collect information on the shop floor
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Visibility of production equipments energy data
Each production line
(Production per line)
Equipment and Installations
Production Management System
Power Management System
Factory as a whole
(Total Production)
Each equipment
(Production per equipment)
Factory
Productio
n Line
Database
Collect energy data in real time
Construct an energy efficient system through analysis of production
and energy data
Improve productivity while reducing energy consumption
Reduce errors and minimizing energy loss
Implement high performance equipment to reduce energy usage
ARC Forum in Pune India, 2011 15
Industrial automation energy solution
Availability of energy information enhances
productivity and reduces total cost
Robot NC
Controller
Devices
Servo Inverter
EDM
Information
linkage
Mitsubishi Electric
CC-Link/LT
Compatible Products
PLC
Laser
Processing
Machine
IA-IT connectivity
products
IT system (MES/ERP)
Shop floor
Meter
Monitor Measure
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Integrated automation platform
Controller & HMI
Engineering Environment
iQ Platform
Controller
Common Platform



HMI
System DB
Sharing between
software tools
PLC
System management tool
Motion
Seamless
communication
Common control platform
Integrated engineering environment
PLC Motion CNC
Robot
Embedded
PC
HMI SVVFD Robot
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Total safety solution
Safety
Level
Scale
I/O
points
Safety I/O module
Small Scale
Safety Control
Safety PLC
Large Scale, Complex
Safety Control
Standalone installations,
small scale safety systems
(10 points)
Multiple Installations and production lines, mid
scale safety systems (tenhundreds points)
Category 4
SIL3
PLe
Category 3
SIL2
PLd
CNC
Motion controller
Monitoring of Safety
Signal
Servo, Inverter
STO
CNC
Monitoring of Speed
Safety controller
Mid Scale Safety
Control
ARC Forum in Pune India, 2011 18
Global Partnership
Engineering
Open Network
IT System
RFID



Safety(/)
VisionBarcode.R ( sw/ curtain) Sensor
Field Devices
Proposal Total Solution
IBM
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Application examples of Mitsubishi Solutions
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Collect operating information, quality information, and tool
information of each process
Winding
wire
Welding
Intermediate
test Molding
Attaching
magnet
Assembling
rotor Balancing
Attaching
magnet
Assembling
Accuracy
measurement
Resistance
test
Pressure
test
Assembling
encoder
Encoder
test
Shipping
test
Quality information
Operating information
Instruction information
Product flow
Production process
MELSEC PLC
(with IA-IT connectivity module)
Operators
Quality
department
Managers
Production
engineering
department
Winding
wire
condition
etc.
Molding
condition etc.
Attaching
condition
etc.
Accuracy of
measurement
Remaining unbalance
amount
Welding
time etc.
Winding wire
resistance
values etc.
Magnet
attaching
condition
etc.
Bolt
tightening
torque etc.
Accuracy
of
assembly
etc.
Average,
resistance
values, etc.
Verification
results etc.
Accuracy
etc.
Verification
results etc.
System
branch
line LAN
Starter production line Rotor production line
Motor assembly line
Quality analysis tool (QC tool)
Line monitoring
Equipment operation analysis
tool
MES Database
Server
Operational
status, tool
information,
etc.
(Operating & quality
management system)

Quality management information,
Operating management
information,
Wear of tool information, etc.
Verification
results etc.
Quality & operation management
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Energy saving with visualization
Utilities
Compressor
Electric
Flow
etc
Production facilities Lighting facilities
Lighting devices
Air-conditioning
Power module
Control module
Product
Quality
Operation
Energy
Demand
Elec
trical
etc
Electrical pw
consumption
Lighting
controller
On/Off
Measurement Production line
Control
Alarm, error
Cont
rol
Cont
rol
Specific consumption management
Manufacturing control of all facilities
Energy management
High efficiency devices
Production & Energy
Management Server
Air-conditioning
controller
On/Off
Measureme
nt
Electrical pw
consumption
Cont
rol
High efficiency devices
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Benefit of visualization
+80%
increase in productivity

+90%
increase in operating rate

-50%
reduction in quality loss

Increased through visualization and
utilization of production information
Increased by referencing
real-time quality information
Reduced by zero defectiveness
with quality control
-20%
reduction energy cost

Reduced through visualization
and energy management of facilities
ARC Forum in Pune India, 2011 23
Integrated common platform (Automotive)
P/T Machining
P/T Assembly
GOT1000
Body Assembly Welding
Reduced
training and
maintenance
costs
Common
platform
reduces need
for spare parts
Common
specification
and easy
engineering
(CC-Link/IE/LT/Safety)
Reduce Total Cost of Ownership
Painting
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Power train assembly
Traceability in power train assembly through
information integration.
Traceability in the power train assembly area
Data traceability through the
MES-IT module
Stable operation without computers
Eliminate unnecessary programming
MES ERP
FA-IT module
Andon Picking Nut runner Sensor
All machinery reports
their status to the MES
server automatically.
Machinery
status
automatically
reports to the
MES server
Achieve
best performance
and reduce TCO
ARC Forum in Pune India, 2011 25
Thank you for your attention!