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Iot Platform Solution for Manufacturing That Connect the Manufacturing Site and Management Through Data

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Iot Platform Solution for Manufacturing That Connect the Manufacturing Site and Management Through Data Manufacturing Solutions to Support End-to-End Optimization FEATURED ARTICLES of the Value Chain IoT Platform Solution for Manufacturing that Connect the Manufacturing Site and Management through Data While initiatives utilizing the IoT are on the rise in the manufacturing industry worldwide, many challenges must be overcome in adopting the IoT. Hitachi Digital Supply Chain/IoT is a solution that Hitachi supplies for facilitating the construction of IoT environments at manufacturing sites. This article looks at the challenges and solutions involved in adopting the IoT. The solutions presented are driven by data and by IoT platforms. Data- driven solutions are implemented by compiling the process flows used to collect data from the manufacturing site’s devices and systems, and using the data at manufacturing sites. IoT platform solutions help improve production eff iciency through systemwide optimization. Shigenori Tanaka Kazuhiro Koura Motoki Suzuki Manabu Naganuma collaborative creation with customers, had grown to 203(1) by the end of March 2017. 1. Introduction Th is growth in number of IoT use cases, however, has revealed a host of challenges that companies are Th roughout 2016 and 2017, the Internet of Th ings experiencing in making eff ective use of the IoT data (IoT) gained popularity even outside the IT indus- collected from manufacturing sites. Th ese challenges try as initiatives such as Industrie 4.0, the Industrial include fi nding methods of collecting data from Internet Consortium (IIC), and Japan’s Robot equipment and devices, recovering the capital invested Revolution Initiative (RRI) worked on many practi- in adopting the IoT, and being able to eff ectively reap cal IoT applications. Manufacturers seeking a com- the benefi ts of the IoT. petitive edge in global markets have started to more Th is article looks at some of the challenges the actively embrace the use of site data to continuously manufacturing industry is experiencing in adopting transform their business activities. Inside Hitachi too, the IoT. It discusses how these challenges can be over- the number of actual use cases of its IoT platform come, and presents an IoT platform solution designed Lumada, designed for creating new value through for the manufacturing industry (see Figure 1). 74. Figure 1 — Overview of Hitachi Digital Supply Chain/IoT (DSC/IoT) DSC/IoT compiles data collection flows from devices at manufacturing sites. It provides a single unified connection to the host system, helping increase the eff iciency of data usage and analysis, and solve site problems. Business management Manufacturing Design/ Research management development Action module standard Visualization/actions Analysis/actions Understand production line and inventory status 24 Individual ID Line name Equipment Worker Time by collecting and A00001 Thermal processing Thermal process 1 9:00 16:00 A00002 Thermal processing Thermal process 1 9:00 16:00 Performs simple analysis visualizing data in real A00003 Thermal processing Thermal process 2 9:00 16:00 A00004 Machining Machine tool 1 13:00 22:00 A00005 Machining Machine tool 1 13:00 22:00 tailored to site KPIs, such as time. #1 13:00 22:00 #1 13:00 22:00 problem and failure sign Collect #2 13:00 22:00 13:00 22:00 detection. Manufacturing 13:00 22:00 13:00 22:00 Feeds analysis results back to site database 13:00 22:00 Establish data collection mechanism by sites to enable actions. creating database of production results. Linking of individual items of data and equipment data Appending and management of background data (metadata) From manufacturing sites to management to sites manufacturing From Automatic data collection Industrial gateway system Equipment/devices, operation control PLC SensorsRobots Process machinery Cameras Workers Plants Plant A Plant B Plant C Plant D PLC: programmable logic controller KPI: key performance indicator and a top-down (IT department-driven) approach. 2. Challenges when Adopting Th is section discusses the challenges encountered in the IoT for Manufacturing these two approaches. (1) Challenges with the production-driven approach Manufacturing sites are adding new IoT-compatible Along with the development of an IoT infra- equipment and refi tting existing equipment with structure, there is a strong impetus to proceed with sensors and communication functions to enable the a production-driven approach toward adopting the collection of various types of manufacturing data. IoT. Th e benefi t of this bottom-up approach is that Wireless technologies(2), (3) developed for IoT networks the specifi c challenges being faced by the site can be are also being used to provide plants with internal net- worked on by collecting the relevant data and linking works for collecting data. But, while this IoT-related it rapidly to solutions. infrastructure is developing, the question of what man- But, a common challenge encountered when using agement approach to use in adopting the IoT and how the production-driven approach is that the work tends to use the collected data are becoming great challenges. to become focused on only the processes for which Th is section covers these challenges in detail. the person in charge is responsible. Th is results in the dispersion of various diff erent data-collection meth- 2. 1 ods and visualization systems throughout the plant or Challenges with Each of the Two Management company, generating multiple separate ‘silo’ systems Approaches at each site that are ineffi cient and uncoordinated. Th ere are two approaches to managing the adoption of Th e greater infl uence a manufacturing site has, the the IoT—a bottom-up (production-driven) approach, greater tendency it has to make its own improvements, Hitachi Review Vol. 67, No. 2 212–213 75. and the more difficult it becomes to tackle common offices in plant departments, restructuring to achieve issues that need to be resolved between processes or companywide optimization or efficiency gains has plants. Activities that apply to IoT should ideally be now created IT departments with significantly fewer approached as management-wide or companywide staff members who can communicate in depth with reforms and implemented simultaneously under strong the manufacturing staff at manufacturing sites or in leadership. But, with human resources and other issues, production management. The IT department-driven these activities tend to be quite far from this ideal. approach also tends to focus more on creating IT (2) Challenges with the IT department-driven platform infrastructure for data storage rather than for approach business processes, overlooking the business require- Largely a top-down approach, the IT department- ments and needs of the manufacturing site. As a result, driven approach to adopting the IoT has the ben- even if a platform for analyzing big data is adopted, efit of tending to favor projects that help maximize there are situations where data is not collected from return on investment to achieve companywide opti- the site, or there is no staff to help ensure effective use mization. But, unlike the days when there were IT of the collected data. Figure 2 — DSC/IoT Product Configuration DSC/IoT is provided by combining an industrial gateway system and action module standard. The industrial gateway system collects data and connects applications. The action module standard is a set of common-function mini apps. • Use of action module standard New separate applications • Dedicated screens and dedicated functions Separate dedicated screens developed and provided Function examples Business functions separately (such as database processing) nSimple web screen data nSimple web display Separate batch functions input/output • Simple dashboard screen: Other • Simple web input screens Kibana (graphing and other functions) • File downloading • Simple dashboard screen: Background image overlay Implementing data from n n n Existing client applications equipment and Data input/output Data processing Action function set sensors, system • MQTT, TCP/UDP • Replacement processing • REST API connection Manufacturing interface as • Standard data store • Range modification • Sending email Equipment common functions • IoT events • Loss/duplicate data processing • Pat lamp interface management execution management • Lumada OT Hub • Generating basic statistics • Speech synthesis/output • FFTs Equipment Sta maintenance management Creation of common Manufacturing interface Quality control via bus Action module standard planning Tool set for edge computing nData input/output, flow control functions nMetadata appending function Bus/hub functions • Database interfaces, FTP server, TCP socket, nMQTT broker function MQTT, AMQP, Kafka, other functions nIoT terminal management function (data connection) nPLC communication function nModbus*1 communication function • Currently supported: MELSEC-Q/iQ*2 (Mitsubishi Electric Corporation), nSensor physical value conversion Base functions FINS*3 (OMRON Corporation) function (data collection) • Supported in future: Siemens AGS7, OPC UA*4, FL-net, JTEKT Corporation nMetadata appending function IoT platform for OT Industrial gateway system (The IoT gateway equipment is mainly composed of VCIMBox made by Hitachi ULSI Systems Co., Ltd. and the HX Series made by Hitachi Industrial Equipment Systems Co., Ltd..) Equipment/sensors (existing/new) REST: representational state transfer API: application programming interface MQTT: message queuing telemetry transport TCP: transmission control protocol UDP: user datagram protocol
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