Wednesday 10 October 2012

We Need Focus To Grow & Sustain Manufacturing

Yesterday, my old friend A.J. Sweatt (formerly from Modern Machine Shop) started a Linkedin Manufacturing Blog with the above title. He started the discussion with: 

Right now, we need a clear vision, clearly enunciated, and easily understood. Instead, we get band-aids and myopia that seem to propel us farther away from the basic economic principals that gave us our manufacturing might in the first place.

His blog is at: http://www.linkedin.com/groupAnswers?viewQuestionAndAnswers=&discussionID=173319289&gid=126939&trk=eml-anet_dig-b_nd-pst_ttle-cn&ut=0MtQjgSASxiBs1

Here is my response:

I care a lot about manufacturing and sustainability as you may know. We initially connected in the late 1990's when you were with Modern Machine Shop magazine and leading them into the digital age. At the time, I was at running Memex and gave you a demo whereby you could control a Fanuc 11M control over the Internet which was a world's first. Now years later, I wonder if the magic has left and familiarity has entered. My Dutch grandmother used to say that "God hides things by putting them near us", and I wonder if manufacturing is suffering from this to a degree.

People hear in the media quite a few negative aspects of manufacturing - such as pollution, layoffs, antiquated technology, waste, globalization, plant closings, out-sourcing, off-shoring, brown fields, stress, injuries, union strife, management greed, etc. Yet our standard of living is dependent on manufacturing once can see why it has been a less desirable choice for young people and an easy target for politicians to either rail against or ignore.

The truth is that manufacturing and the principles that run it are everywhere. Lean principles, reduction of waste, management practices and even sustainability are ideas that have made a real difference in this world. I would argue that manufacturing - done right - is the one of the greatest wealth producers (rather than wealth re-distributors) ever invented.

Our growing society wants to have abundance and enough for all. This laudable objective requires wealth creation, good stewardship and excellent systems. Thomas Jefferson once noted that "great wealth and great poverty cannot co-exist in a democracy".

Indeed, Konosuke Matsushuta the founder of Panasonic in Japan created in 1946 a "Peace and Happiness Through Prosperity" plan that understands the link between peace and the economic well-being (see http://www.php.co.jp/en/think.php). The PHP movement is quite large today by the way.

A few years ago I have started a group called "Peoplewerks Volunteer Association" to put people back to work one day at a time (www.peoplewerks.com). People need to have something meaningful to do, and enough money to live and fuel the economic engine (Henry Ford had it right).  The waste of a human resource is our world's worst oversight in my opinion.

In summary then, I believe that manufacturing in its broadest transformative context is the key to dream of enough for all in a sustainable way. We just feel better making the world a better place for others. I say let's manufacture the future together...

Friday 5 October 2012

Microsoft's Long Standing Interest in Manufacturing


I came across today this entry that I had made to Tyler Bryson's Blog, who was at the time the point person for Microsoft's Manufacturing Strategy. Although it is old (Aug 30, 2010), it is interesting to see how long Microsoft has been involved in this space. My comments were designed to welcome him (and the Microsoft Blog) into this manufacturing space, and let him know that we have enjoyed Microsoft's long standing interest in our sector. 

If I could talk to him today, I would ask about Microsoft's "Green Project" as it applied to manufacturing. I was told this summer at the Microsoft World Partner Conference in Toronto that the initiative was stalled when Steve Ballmer took over Microsoft and I wonder why. The "Green" initiative was to help manufacturing and I think we should open this up again...

Check Out Microsoft's "Manufacturing Matters" Blog at:

http://blogs.msdn.com/b/manufacturing/

Also of interest was Tyler's first blog posting way back in 2008:
http://blogs.msdn.com/b/manufacturing/archive/2008/07/28/manufacturing-matters-to-microsoft.aspx


By the way, the current US Manufacturing & Resources General Manager for Microsoft is now Craig Hodges and he is continuing to highlight "innovations and ideas from across Microsoft in Manufacturing" in the Blog.

-------------------------------------------------- 

Tyler - I know that this is an old Blog - but I just wanted to welcome you to the manufacturing space.

Microsoft has actually been interested in and sponsoring events in our space for years. When I was with the Global HMI Sub-Committee in OMAC (Open Modular Architecture Controls group), Microsoft had a MUG (Microsoft User Group). We are talking over 10 years ago, before OMAC joined ISA and when it was under the ARC people's direction. Back then, I was running an upstart company after I had coined a new name that quickly became a category, namely "e-Manufacturing". After writing the first widely accepted XML Schema with Dr. Stephen Lane-Smith, I was happy that it has been used in the last few years and added to by MTConnect (see MTConnect.org) with sponsorship from the American Machine Tool Association. I now am involved with MTConnect on their Technical Advisory Board.

Our dream of barrier-free connectivity is now coming to pass and Microsoft will be a player in this. Our software systems over the years have relied heavily on Microsoft products - at times this was trying, but at least a standard could be leveraged for all. Today our goal is to connect the millions of isolated machine tools and provide a cloud of "machine2machine" inter-connectivity and synergy. We look at the plant as one machine now, and are in some ways living up to the 1998 press in Modern Machine Shop we got under the Memex name as the suppliers of the "shop floor nervous system".

I want to leave you with a thought - back in the DotCom days (yes, we were one of them - TSX:MFG) I explained to the VCs that wondered about this connectivity thing, that what we were talking about was the equivalent of clicking buy on the Net and the machine would almost instantly start making the product you needed. We are talking of a "Zero waste - made to order - ultra high velocity of data flow - integrated - quick response - perfect orders" - type of thing and all JIT! We want to leverage IT on the factory floor and with my new team of over a dozen companies, and with the technology we have today, I do not see why we cannot have this "click-buy-make-ship" dream.

Friday 14 September 2012

Manufacturing Today - Walking IMTS 2012 in Chicago

Well I just got back from the International Manufacturing Technology Show (IMTS 2012) in Chicago. What a spectacular show with over 1900 exhibitors, miles of isle ways, every building used at McCormick and a great crowd of people. IMTS comes around once every two years on the even year, and the last one was just before the financial meltdown that no one seemed to see coming in Sept 2010. This week over 100,000 manufacturing people came to see what was new, and where they could improve their operations.

My observations are as follows:

1.    Manufacturers are gearing up these days for "re-shoring," where jobs subcontracted to China and other low-cost "off-shore" countries are coming back. As such, they need to seek out new technologies to stay competitive and nimble. The use of technology, automation and the greater leveraging of information technology is clearly evident. From small inverted hexapod mini-assembly machines at the Fanuc FA booth in the South Hall, to the half dozen folks selling tooling vending machines in the West Hall, we see a drive to automate everything.

2.    The East Hall was filled with software technology providers that are focusing on Overall Equipment Effectiveness (OEE), real-time machine monitoring, energy management, CAD/CAM and better MES/ERP integration. A common theme was the adoption of MTConnect, but today it has more software applications than native machine types. The complaint from these software vendors was that people know they need information, but are wondering how to get the connectivity and grappling with the user interface. From bar code readers to hand held terminals, touch screens to the leveraging of optional machine protocols - everyone knows that the last few inches is where the MTConnect movement will need to focus to gain greater traction.

3. The South Hall had spectacular million dollar booths from industry veterans such as Mazak, Makino, Hyundai, Hurco, Haas, OKUMA, Methods, MAG and so on. It is not every day that you see two story booths, bars serving alcohol, robots moving train wheels in a Flexible Manufacturing System (FMS) cell. It was a feast for the eyes and probably the most advanced display of manufacturing ever - and I have been going for 22 years!

4. The North Hall had smaller booths with EDM, grinding, saws, DNC, tool management, metal suppliers, you name it - the entire manufacturing world was represented. A sales rep from Hyd-Mech, a company in the fabricating cut-off saw business, admitted to me that IMTS is a place you have to attend, but for them they get 3 times the sales from their specialty FabTech Show in Vegas. That said, he admitted if you don't come, your customers and competitors will assume you are out of business. So IMTS is a place to be seen and catch up with the industry for sure.

5. The emerging technology area still had an MTConnect booth staffed by TAG and Institute staff members like Paul Warndorf - but this is probably the last year for it as it is 6 years old now. Some new applications using iPads were shown by Joel Neidig from ITAMCO and Ken Tock from MacKintock demonstrated their iPad and HMTL5 dynamic web-based MTConnect factory floor emulation and data feed which was impressive. John Turner and Will Sobel, two of MTConnect's main technical architects, took the time to explain to Paul Hogendoorn, an electronics entrepreneur and tech writer with Manufacturing Automation in Canada, what MTConnect's main value equation was. In short, MTConnect is an open web-centric schema that acts like a common dictionary for the manufacturing connectivity world. That means developers and users always know what and where data can be found in any MTConnect appliance and the simple, expandable common interface that will enable future plug n' play integration economies. In simple terms then, gone are the days when you were locked into poor communication options, expensive protocols for each and every machine, or heavy costs to migrate to new technologies as they came along. Once again, the industrial democracy is demonstrated at its' best here and we all benefit. The extensible open aspects of MTConnect are now using "Read/Read" to safely get dissimilar equipment talking fast. As an electronics developer, and former manufacturer himself, I think that Paul "got" the MTConnect value equation and realized that the next big hurdle is legacy connectivity.

6. It was great to connect with vibrant Diane Pepi at Methods Machine about advances in Yasnac third party products. Nexas is looking to soon supply the Yasnac J300 memory module and Methods is the Matsuura dealer in North America that focused on Yasnac controls before they stopped producing. That said, it is clear that the memory upgrade and DNC market are soon to be eclipsed by technology that makes every machine a node on the corporate network. Jim Brown from Makino pointed out that all his machines have Ethernet connectivity, but it is the old ones they worry about as more and more clients see the benefits of inter-machine inter-connectivity on all their machines Makino or not. While we waited for MAG VP Jeff Price, PJ pointed out to me late on Tuesday afternoon that all the machine monitoring solutions they sell still need better legacy connectivity. So much can be done to help operations and plant floor visibility if we can just elegantly bridge the last few inches - a theme we have heard before. With Dave Edstrom, Chair of MTConnect, calling for abstracts by Oct 1 for the next MTConnect [MC]2 Conference in April 10-12 at the Hyatt Regency Hotel in Cincinnati - this topic needs to be addressed before then.

7.   Finally the theme in the emerging technology booth was all about additive technologies. Teams converging on a trick car design in this area also highlighted that global engineering teaming and skunk works will be a future reality. Solid modeling seems to a standard  on the all the CAD/CAM software offerings in the East Hall as the world gets robots and automated handlers to reduce waste, shorten development time and save energy for better sustainability and cost control.

In summary, IMTS 2012 was for me a great eye opener as to the advanced state of manufacturing. I found the attendee mood was upbeat with serious buying on people's minds. We seem to want to do more with less, and do it faster than ever. Sophisticated electronics control systems are in almost ever single manufacturing tool these days, and the next drive will be to interconnect those islands of automation. I predict that when one looks at the cyber factory floor of the near future, they will realize that it is really one big machine with many connected parts - all connected with a shop floor nervous system.

In short, I foresee that machine tools will soon just be like USB metal printers that plug into the system, mount and run together easily in the very near future...



Tom Gaasenbeek - Find me on Bloggers.com

Tuesday 19 June 2012

MTConnect Day 1 - Legacy Connectivity Status

John Turner from  FAC&T talked about the legacy machine integration challenge. A call for more MTConnect Legacy Connection devices was emphatically made. The Tipping Point for MTConnect will be related to this last few inches of connection into the machine tool. Right now the following connection types are:



Native Type Machine (20-30% of Machines)
  • easiest to implement
  • machine tool builder - product source and support
  • Limited Hardware/Software Issues
Translation Type Machines (10-20% of Machines)
  • control Builder or 3rd party - product source
  • Hardware Issues - Communication Board on Control, PC to Host Adapter/Agents
  • Software Issues - No Commercial Adapter/Agent Available, Software confguration to data source
Connection Unit Type Machines (50% or More of Machines)
  • Works with any machine
  • 3rd Party - Product Source & Support
  • Power Line Monitoring and I/O Interface Types Available
  • Technical Issues
    • Installation & Wiring (I/O Type)
    • Power Profile Learning (Power Line Type)
Other Lessons:
  • Shops want a guide to determine how their machine can connect to a network using MTConnect?
  • What information can I get from the shop floor and can O get the data I need from my machine?
  • Most requested information
    • Process Visualization/Production Dashboard
    • Machine/Spindle Utilization
    • Maintenance
    • Tooling
    • Data logging
    • Part program ID, operator ID and part ID
Recommended Enhancements to Connectivity Guide
  • Machine Data sheet
    • Add space to capture "Work Area (Machining cell)" associated with a machine
    • Add space to capture "MTConnect connection Type" for a Machine
    • Add space to Factory/Site to support Multi-Site Operations
    • Add space to capture Controller or HMI Operating System versions
  • Overall Readability/Effectiveness of the Guide
    • Improve readability by rearranging sections and tailoring language to the audience
    • Add recommendations on what to monitor, perhaps based on what has been learned in the field
    • Include data types used by each of the known software solutions 
Call for A NTMA Starter Kit

Pat Walsh, VP of the NTMA, called for an easy to install "MTConnect Starter Kit" made available to the National Tool Manufacturing Association 1000 members. We need a standardized kit for machines using MTConnect to a dashboard. Looking at October 24-28, 2012 at the NTMA Conference and then again at the MFG Meeting March 5-10, 2013.

The kit must be easy to install, work on a wide range of machines, attractively priced and scalable.

What do the NTMA membership want to see on the dashboard?
Pat responded -> is it running, parts count, what part is running, machine utilization, etc...

Implementation Note

Nexas Networks is focused on economical MTConnect shop floor connectivity but we have added in embedded DNC. Our Nexas DCAM ideas that run under the DNC engine enable very low cost MTConnect implementations which may be perfect for the NTMA starter kit idea. The software will be the differentiator in the end, but the price has to be economical and let the software application vendors need to compete for the final sale to the NTMA member.

MTConnect TAG - Day 1 Parts Session 4 - June 19, 2012

In MTConnect, a new working group has been formed relating to Parts and it is being lead by Jim Smith of Nexas America. The first phone conference was only June 5 and the second June 17, 2012. Below is a summary of what has been discussed thus far.

Transformation Model
  • Stock
  • Work Piece
  • Operations
 Production Status Model
  • Material Reveved
  • Operations
    • Setup/ In Process / Completed
    • Expected process time
 Tracking Model
  • Material information
  • Source
  • Lot Number
  • serial numbers, batch and lot numbers
  • process information
  • part programs
  • machine
 Available Resources
  • Dimensional Metrology Standards (QIF)

Production Resource Model
  • Operator
  • Machine ID
  • Start Time
  • Process Information
  • Safety data
  • Manual processes
  • assemblies
  • tertiary data
  • fictures
 Additional Items
  • Part ID - Part Program file name - DNC functionality
  • ITAR - security
Project Scope and Goals
  • take a phased in approach
  • separate buckets
  • have a draft for IMTS
Next Steps
  • Jim works with others to create a document for people to throw stones at it.
  • create a schedule with an eye on a draft release before IMTS
  • seek additional user members
Part Definition (DRAFT)

"A single identifiable item that has defined characteristics and is created by applying a series of one of more processes to raw material or to another part."

Look to STEP-NC for a lot of the part information. John Michaloski from NIST referred to STEP-NC 14649 and that it could be a great basis for a start here. He also mentioned that the full STEP-NC APT238 has all the STEP models, but it is a bit unwieldy - like "sipping from a fire hose". Also it was discussed how this data may be up in the engineering office, or the MES system and not necessarily available at the machine. We can also embed some of this STEP-NC parts data in an RFID tag with the part and thus enabling traceability. 

"Smart Comments" in RS-274 are another way of adding the rich data to MTConnect.

Josh Davids from Scytec talked about using the DNC system to auto-insert ERP data into comments on remote call file. Will Sobel mentioned that DNC needs love right now in MTConnect.

Discussion of Operator Requirements

Human Assets Tracking Discussion - track operator or maintenance working with the machine. An operator ID and perhaps roles could be monitored. Also Tom Gaasenbeek of Nexas Networks  mentioned the need MTConnect Human Asset tracking for operators to address ITAR compliance concerns, In these defense centric operations only qualified people should be able to download controlled part programs, or even log into a machine for instance.


MTConnect TAG Meeting in Plymouth Indiana - Day 1 Morning Sessions 1-3, June 19, 2012

I am in Plymouth, Indiana today at the latest MTConnect Technical Advisory Group to work on the latest Ver 1.3 MTConnect XML schema. I thought I would add in this blog entry the notes for this meeting to show what the MTConnect members are thinking at this point. The general feeling is the MTConnect is now broad enough to offer real value as a universal connectivity standard on the factory floor.

Introduction:

The meeting has several thrusts - namely solidifying Ver 1.3 of the standard, getting ready for IMTS in Chicago Sept 10-15, 2012 and introduce the new Parts and Production Information Working Group led by Jim Smith of Nexas America. Courtney Hill from GE Aviation (retired) and the MTConnect board member gave the intro.

Session 1 - OPC Discussion

Will Sobel of Systems Insights, started talking about the MTConnect-OPC UA Companion Specifications. The integration of the OPC standard will help address the limited information from the PLC tag map for MTConnect purposes. The SDKs of the PLCs are dependent on which type of PLC you have, which makes integration tough. MTConnect linked with Randy Armstrong from the OPC Foundation - but he is now a consultant these days.

OPC has traditionally been a window of access to PLC data, but control information may be possible to access - but it can be limited and case specific. MTConnect should look into this to address the process industry including automotive which often bridges the CNC/PLC technologies. PLCs are embedded into CNCs, but they are often used in conjunction with discrete manufacturing so addressing this market will make sense. Also the process world has a host of well developed software applications that can be leveraged with MTConnect.

OPC UA uses XML and runs out of the controller these days, rather than leveraging the external DCOMM market so it is a natural fit with MTConnect and the XML schema it is based upon. Legacy integration may also be aided here. Call for interest by Dave Edstrom (MTConnect Chair) - time, money, expertise...

Session 2 - Mobile Assets Group

Major changes for Ver 1.3 include the inclusion of the Cutting Tool Archetype.

Points included:
  • protocol enhancement to support a lighter framework for actual usage in the field
  • retention knob detail
  • material removal
  • tool (asset) location information

Archetypes vs. Instances

The Archytype contains the static information that is the same for the entire class of tools. This is information from tool libraries. The Archetype is an abstract tool. The Cutting Tool (instance) contains the life cycle data for the physical tool. This will correspond to a single assembly with ID, life cycle data etc - hard data from a specific tool.

The need to represent Cutting Tool Data when information about individual assemblies is not present. Archetype has the same structure as the Cutting Tool except for the following:
  • status
  • tool life
  • CuttingItemLife
  • measured values will be only nominal values

Cutting Tool (instance) has the CuttingToolDefintion now deprecated - it can only be used in a Cutting Tool Archetype.

ISO 13399 Part 28 XML (versus Schema is in EXPRESS format as represented in Part 21)  is the ISO standard for tool definitions.

A machine tool may only know the following:
- asset ID
- Location
- Length & Diameter
- Time in Use

Separating the Archetype allows for a much lighter data package - better for RFID.

Asset Removal

- an asset can now be removed from the agent
- the assets are marked as removed, so that they can still be accessed
- an AssetRemoved event is sent when the asset is removed
- an application can request the agent provides both removed and active
   assets using the "removed=true" URL argument
- when an asset is removed it is not moved to the front if the MRU list
- an attribute has been added to the Asset as well as any sub-type of Asset (like cutting tool)
- helps with tracking

Retention Knobs and Locations

  • part of manufacturing process no currently covered in ISO13399 standard
  • process specific information needed to be added to MTConnect
  • tool location needs to be addressed - carousel on the CNC, racks, carts, bleachers, cribs etc...

Questions From The Floor

What about work holding?
Can this asset group handle people resources - or where does this resource fit?

Session 3 - Accessory Equipment & Inter-Device Connectivity

Started with bar feeder integration - simplified interface model with minimal changes to MTConnect. There are Open Source tools available for implementation, Two successful proof-of-concept implementation with y LNS/Mazak and EDGE/OKUMA.

Right now the Legacy Digital IO Protocol is used there - 10-16 I/O points needed - but limited. Current model is Read/Write by the bar feeder to the CNC. The MTConnect model is passing data, not bits. We need a common vocabulary for all vendors. Make a less brittle interface (to "Future-Proof" yourself) by decoupling from the decoupling from the static register mapping. MTConnect supports "near-real-time" data monitoring. The protocol supports report by exception to optimize resources - using the MTConnect push protocol with a request at 0 milliseconds - send when a change occurs in other words.

MTConnect provides a higher degree of failure detection:
  • Heartbeats on all communications
  • Immediate detection of failure
  • Real-time push protocol - with minimal overhead, only get what you need when it changes

MTConnect is self-healing - states asserted once connection is re-established.

Simplified Interface

- moved away from new category of data item - using events with CDATA indicating state;
- moved all data describing the Stock into the Assets model:
  • Now we don't have to create a lot of additional data items that will have static values for a given piece of bar stock;
  • It creates a richer document model for representing bar stock;
  • It will be synchronized with work done in the Parts Group
  • It has a small delta to existing specification
- open source tools available - Bar Feeder Simulator
- there was no performance or reliability degradation using MTConnect here

Benefits

Rich  data means better decision making - better monitoring, better use of stock, better scheduling and processing, better (and easier) integration, tunable failure detection, less downtime, etc...


Neil Desrosiers from Mazak shared that the benefits of MTConnect far outweighs the costs and that customers have already enjoyed the additional data available in additional to the legacy I/O interface. customers want more and MTConnect is the answer to their needs - and it is expandable for the future.

Check out Mazak's MTConnect offering at:

http://www.mazakusa.com/MTConnect/MTConnect_Brochure_7_15_2011_For_Viewing.pdf

And Beyond...

Adding asset monitoring and control of bar feeder manufacturing assets, extend to other factory components:
  • robots
  • chip conveyors
  • high pressure coolant
  • pallet systems
  • etc...

What is Still Needed?

- MTConnect needs a Discovery Model for MTConnect devices
- SSDP (Simple Service Discovery Protocol) is widely used and could be adopted here
  •    UPnP or DLNA uses it for service discovery
  •    All networking issues have been solved
  •    Many open source implementation are free to use
  •    Multicast based
- secure pairing of devices (like BlueTooth now)
- need to work on UUID scheme
- this is really needed
- dynamic, distributed, lower maintenance than LDAP
- limited broadcasts to sub-net which is great using multi-cast
- it routes (and is widely accommodated in current IT paradigm)

---

Stay tuned for the Parts Group Next....

Tuesday 10 January 2012

Holonic Manufacturing - An Introduction

I want to introduce the concept of Holonic Manufacturing, as I believe Computer Integrated Manufacturing (CIM) will continue to move in this direction now that connectivity, interoperability and cloud-based networking are present. Areas of security, rules based systems and distributed architecture will be addressed in later blogs as we develop this Holonic theme.

HOLONIC MANUFACTURING

Manufacturing has changed a lot since its beginning, especially for the last decades. These changes are not only technology-related, but also concern the way customers interact with the manufacturing system, the environment that must be preserved, the shorter product's life-cycle, etc.

Until a few years ago, the Computer Integrated Manufacturing concept was considered satisfactory enough for treating enterprise/manufacturing requirements. However, taking into account a new set of organizational and economic concepts, it becomes clear that the centralized CIM approach is not the answer. On the contrary, the requirements for today's and future manufacturing systems suggest autonomy, distribution, and flexibility, while stressing the need for co-ordination amongst production units. It is expected that rigid, static and hierarchical manufacturing systems will give way to systems that are more adaptable to rapid change.
 
It is at this point that agent technology is adequate. An agent is an autonomous entity, maybe intelligent, that pursuits its own goals and, eventually, it may cater for the user's ones. Some authors would like to augment this definition in order to incorporate social ability, mental behavior (e.g. knowledge, beliefs, desires, and intentions), and learning.
 
A Multi-Agent System (MAS) is a population of agents that exhibit social behavior and are capable of interacting with each other in a co-operative fashion, while simultaneously each agent may pursue individual objectives. This interaction assumes some kind of communication language (e.g. KQML  and perception of the surrounding environment. The use of a multi-agent architecture will make the decisions be taken in a decentralized way.
 
Agent-based systems are "best suited for applications that are modular, decentralized, changeable, ill-structured and complex", and with a "great number of interactions among components".
 
On the other hand, a manufacturing system may be characterized by:
  • Its functions (e.g. production planning, production scheduling, inventory, etc.), which can be seen as modules;
  • As it was already referred, the traditional CIM centralized architecture is not satisfactory for today's manufacturing requirements; new manufacturing systems must be decentralized manufacturing systems;
  • Physically, a manufacturing system is based on resources (e.g. numeric control machines, robots, AGVs, conveyors). The number and configuration of these resources may change during the system's life time;
  • Since the manufacturing process is a dynamic one (e.g. suppliers and consumers in a supply chain may change many times) it is impossible to know the exact structure or topology of the system, thus being ill-structured;
  • The number of products and orders, as well as different alternative production routes, count for the highly complex nature of the manufacturing systems.
Therefore, it seems that a framework based on the principles which the Distributed Artificial Intelligence (DAI) and Multi-Agent Systems (MAS) paradigms were built on, appears as the most natural solution for the new generation of manufacturing systems. This methodology will allow the modelling of a system as a set of intelligent, autonomous and co-operative elements in order to achieve reconfigurable and extensible architectures.
 
On the manufacturing arena, these two paradigms (DAI and MAS) are best represented by the concept of Holonic Manufacturing Systems (HMSs). The idea behind HMSs is to provide a dynamic and decentralised manufacturing process, in which humans are effectively integrated, so that changes can be made dynamically and continuously.

As Agent-based Manufacturing relies on the notion of agent, HMSs are based on the notion of Holon. Arthur Koestler coined the term "Holon" from a combination of Greek holos (whole) with the suffix on which, as in proton or neutron, suggests a particle or part. A Holon means simultaneously a whole (to their subordinated parts) and a dependent part when seen from the inverse direction. Thus, a Holon can be made up of other holons.
 
This aggregation of holons inside other holons is called holarchy. An HMS is a holarchy that integrates the entire range of manufacturing activities from order booking through design, production, and marketing to achieve the agile manufacturing enterprise.

This article (and image) are quoted from a good resource paper on the Holonic Manufacturing subject (see http://sic.ici.ro/sic2000_2/art02.htm.) My source acknowledgement goes to:

Paulo Sousa & Carlos Ramos
Departamento de Engenharia Informática
Instituto Superior de Engenharia do Porto (ISEP/IPP)
Rua São Tomé, s/n, 4200 Porto,
Portugal

Wednesday 4 January 2012

MTConnect Needs/Usage Survey Results

A few weeks ago, I posted an MTConnect needs/usage survey and I thought I would list some of the preliminary results now. Here is a quick summary of the answers, for those that are interested:

1. What would you use MTConnect for?

Our answers found more or less equal interest in OEE, Machine Monitoring, Production Planning, Lights Out Manufacturing, Operator Management & Flexible Manufacturing Systems. I expected OEE and machine monitoring, but the others are interesting extensions that have been largely lacking on the factory floor probably due to their high cost and the complexity of previous solutions.

2. What is holding you back from adoption of MTConnect?

People answered that they didn't know what MTConnect was yet...

3. Do you have anything for real-time monitoring now?

Yes - but it looks like MTConnect will do a better job.

4. Do you have a DNC system?

All do...


5. Do you have LAN or WiFi on the factory floor now?

50% do and 50% don't


6. Talk further about this?

Yes - keep the conversation going - there is interest here...

Anyway, these are interesting results. It shows that MTConnect is still an unknown entity, but people are looking to use this for some substantial applications that up until now have been a challenge to successfully implement. The tracking of production is not quite the same as machine tool monitoring. MTConnect can basically enable quite a bit, but the real issue is connectivity. It always comes down to the value equation - what pay-back do you get for the investment in MTConnect. Obviously, more discussion is needed here - so we will make that happen this blog in future entries.

Happy New Year all...