““Towards the CYBER FACTORY”Towards the CYBER FACTORY”

versalog

Colin Hales

Agents Lab/VicAgents Lab/VicFri April 26 2002Fri April 26 2002

colin@versalog.com.au

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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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

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

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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- - “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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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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State of TechnologyState of Technology

Issues:Issues:

SensorsSensorsCommunicationsCommunicationsProgramming LanguagesProgramming LanguagesHMI/SCADAHMI/SCADAOperating SystemsOperating SystemsBUS standardsBUS standardsCPUCPU

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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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State of TechnologyState of Technology

Buying HabitsBuying Habits

The ONE STOP The ONE STOP SHOPSHOP

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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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- - “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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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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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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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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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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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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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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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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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……..