PROJEKT: E! 4177 PRO-FACTORY UES Ubiquitous oriented embedded systems for globally distributed factories of manufacturing enterprises 1.7.2008-31.6.2011 LITOSTROJ POWER – STATE OF THE ART Background, field of expertise, activities within project Boža Pustovrh Martin č i č & Borut Rihtarši č LITOSTROJ E.I., Ljubljana Kick-off-meeting Gijon, 13 th November 2008 2 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
E! 4177 PRO-FACTORY UES Contents: • Introducing • Background • Field of expertise • Activities within project 3 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
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EUREKA EXPIRIENCE • E! 1156 INTO ISYTRANS Development And Integral Structuring Of Technology, Methods Of Organization, Man And The Environment For Implementation Of Organization Concepts Management Structures In The Field Of European Railroad Track Vehicle Construction. (1992-1994) • E! 2404 Eureka-Factory EURAS Market oriented flexible assembly processes, Germany, Hungary, Sweden, Slovenia, (2000-2001) • E! 2612 Eureka-Factory COSAP : Customer -oriented design of on- site assembly processes, Germany, Hungary, Sweden, Slovenia, (2001-2004) • E! 2736 Eureka-Factory TRUST : Use of Regional Potentials With Respect To Problem-Solving Processes in Production Germany, Italy, Slovenia, (2002-2004) 9 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
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BACKGROUND AND MOTIVATION Manufacturing issues • One of the most important characteristics of the modern manufacturing and fabrication business is its complexity and non determinism (inputs are non-deterministic, system is unstable, environment is unpredictable). • Project management and order development in modern network organisation are preformed in distributed environment. • In dynamically changing environment, important requirement for effective management and control of a workshop is efficient and accurate monitoring of production, decentralized decision making and an efficient co-ordination of autonomous interacting entities. • The basic problem is that we deal with inaccurate production data, which leads to inaccurate reporting and consequently poor non- optimal decisions. 11 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
BACKGROUND AND MOTIVATION 12 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
OBJECTIVES • to build an autonomous system for decision making shop floor control, • designed in such a way that different types of users can address different levels of information, • accessible anytime from anywhere, • access for different type of Log-in users, • data and access security, • fully integrated solution (ERP, CAD, CAPP,…), • easy navigation, • no extra software needed (only web browser), • build on and with the latest programming technologies and tools (.NET technology). 13 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
PROJECTS LEADING 14 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
OBJECTIVES Enterprise leading Company Management Multiproject coordination Level [looking for global solution] Department Department Project Management managing managing Level Function Function managing managing Operational & Resource Management Level Function Function realization realization IN OUT 15 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
CURRENT SITUATION in IT & GAP 16 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
IT MODEL of PRODUCTION COMPANY 17 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
WORKSHOP MODEL (functional view) HIGHER LEVEL PROJECT OPERATION PLANNED PLANT MANAGER COORDINATION STATES WORK ORDERS PLANT CONTROL SYSTEM WORKSHOP SCHEDULING OPEARATION DETAILING WORK ORDER IN PROCESSING WORK MICRO PLANNER MANAGER WORK MANAGER INSTRUCTIONS DOCUMENTATION DOCUMENTATION DISPATCHING WORKSHOP CONTROL MICRO PLANNER WORK PIECE MATERIAL PREPARATION OPERATION TOOLS OPERATION CONTROL STATES PREPARATOR COORINATION WORK PLACE PLAN (RESOURCES) OPERATOR SYSTEM BDE / MDE / CAQ 18 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
WORKSHOP MODEL (functional view) HIGHER LEVEL PROJECT OPERATION PLANNED PLANT MANAGER COORDINATION STATES WORK ORDERS PLANT CONTROL SYSTEM WORKSHOP SCHEDULING OPEARATION DETAILING WORK ORDER IN PROCESSING WORK MICRO PLANNER MANAGER WORK MANAGER INSTRUCTIONS DOCUMENTATION DOCUMENTATION DISPATCHING WORKSHOP CONTROL MICRO PLANNER WORK PIECE MATERIAL PREPARATION OPERATION TOOLS OPERATION CONTROL STATES PREPARATOR COORINATION WORK PLACE PLAN (RESOURCES) OPERATOR SYSTEM BDE / MDE / CAQ 19 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
BASIC ELEMENTS OF IMPLEMENTATION • Web technologies: ASP.NET (Active Server Pages) as programming environment, C# as primary programming language. • Relational Database Management Systems (RDBMS): SQL Server 2005 on Windows Server 2003, T-SQL language for data retrieval. • Visual Studio 2005.NET Professional edition for web application development & Touch Panel PC desktop application. 20 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
DIFFERENT TYPS OF PRODUCTION COMPANIES • ETO – engineering to order (welding, machining , assembly) • ATO – assembly to order • MTO – manufacturing to order • MTS – manufacturing to stock • Develop for each type is needed. 21 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
OPPORTUNITIES 1. Production of welding parts process 2. Delivery, transport and build in process 3. Logistics in assembly department: preparing assembly parts, warehousing and internal transport 4. Development documentation in workshop: tracing, changing control CHALLENGES: planning & controlling, transability, quality, tracking & tracing 22 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
WELDING PARTS PRODUCTION PROCESS • A lot of different products at the same time • Big dimensions (to 5 m and more) • Each product is made of a lot of welding parts (sometimes over 100) • Information are very important: – More than 5000 operations per month (to plan & control) – About 10.000 different documents every month (working orders, transport documents, drawings, sketches, heat treatment charts, welding book,…) 23 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
WELDING PARTS PRODUCTION PROCESS - Motivation • A need for advanced control of process (exacting piece of work to order) • No appropriate products on the market for support information flow in ETO production • Development of theoretical concepts on production cybernetics (definition of EWS, collaboration work concepts in distributed environment) • Development on information communication technology (net technology, VPN, RFID feelers,…) • Good experience with our system (shop floor support by net technology) 24 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
WELDING PARTS PRODUCTION PROCESS - Need To develop a system, which offers: • Prepared input information about technological procedures and production planning data • Support by planning and scheduling • Collecting data about tasks, work equipment and work systems statuses, process parameters and product quality characteristics • Production situation evaluation and its characterization with performance indicators • Making decision on authentic (reliable, trusty), up-to-date information and on prepared scenarios for standard procedures (work and typical problems) 25 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
WELDING PARTS PRODUCTION PROCESS - Request • More than one worker at the working place • Tracking the worker, who works at different places during the working day • Exacting planning process (welding and machining change during production) • Traceability: – Who worked on the specific product – Welding parts (from cutting to – Process parameters (electric current, voltage, welding velocity,…) – Quality control data (penetrant fluid inspection, ultrasound inspection, visual control,…) 26 Boža Pustovrh Martin č i č , E!4177 – Ubiquitous embedded systems, Gijon
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