ARC Forum in Pune India, 2011

Optimizing the Total Factory

Through Integrated Automation Solution

August 2, 2011

ARC Forum in Pune India, 2011 1

 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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 Needs in the manufacturing industry

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 informatization of the production floor

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 Do you know your operation?

Meeting
1% Takt time
Shutdown Upgrade
4% etc ↓
6% part optimization
Startup
2%
Shortage
10%
Running time
52%
Tooling change
Planning 22%
Step up operation
↓
total optimization
Trouble
2%
Data is needed to understand production status!

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 Difficult to collect data from the production floor
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)
Before adopting IT
Operation process A Operation process B Operation process C Inspection process Performance results input

・Extra work by manual operation

Operating Operating Operating Operating ・Delay in final processing
instructions instructions instructions instructions ・Delay in information transmission
due to inaccuracies
Via media and networks
Performance data Performance data Performance data Performance data
entry entry entry entry
Information Systems
Omissions and recording mistakes (wrong entry), inaccuracies due to mass entry, etc.

After adopting IT Performance management using

information systems
Operation process A Operation process B Operation process C
• Performance report directly from device
Production site Production site Production site Collect detailed information that
terminal terminal terminal cannot be extracted manually Production
• Quick, accurate information planning system
・Operating ・Operating ・Operating Detect not only the issue but also its
instructions instructions instructions
・Performance ・Performance ・Performance primary cause
data input data input data input
Delivery
Performance data response
system
Via network
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 Seamless communication between IA and IT
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

ERP/SCM Plan Adjustment

Business Layer

Information Linkage
(Enterprise)

MES Application Layer Analysis

Execute
(Manufacturing Execution System)

Controller Control Result

＋ Control Layer
Equipment (Production Facilities)

Product Linkage
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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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 Factory-wide optimization

Need solutions to share and integrate information

① Vertical Integration
IA-IT connectivity provides visibility of production and controller
information
Links different information layers

② Horizontal Integration

IA-IT connectivity
Seamless communication
among components
Linking products
throughout
manufacture
layers
Integration of components
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 Feels like 1 System, 1 Engineering Tool
High speed transmission of control and synchronization data
among controllers
Share information among controllers and engineering tools
① Reduce TCO(Cost reduction in design, maintenance, and application steps)
② Achieve best performance possible

Motion Communication
System
PLC
Design
Embedded Data
System Collection

CNC Programming
ＳＣＡＤＡ
PC
Information Monitoring
Robot
Integration

Common Controller Platform Integrated Engineering Tools

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 Integration of Safety Control, Derives, and Devices

Intrinsic safety (guard management) and functional safe

Requirements The right safety components in the right places
for Factory
Safety Safety control through visualization of safety data

Safety Control Effective utilization

Lineup for different scales and visualization of
Large Small safety data
MELSEC-QS Safety relays
Middle

Safety PLC
Seamless Network
Safety Drives Total Safety
Connectivity between Safety Devices
safety control and safety Solution Synergy with safety partners
drives
CNC VFD CC-Link Safety Total solution
connectivity (switch/sensor)
Servo

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 Integrated & Open Network Structure

Seamlessly transmit control information throughout the system

Large Low

Computer
level network
Information
Seamless communication Data
data capacity
communication
Controller Real time
level network MELSECNET/H performance
Distributed control

Device
level network
I/O control Motion control
Small High

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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
① Detect changes
Collect data Embedded ② Reduce stress
③ Programless
Information system
④ High Reliability

Automation Resolve
system performance, cost,
and reliability
problems
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 Collect information on the shop floor
Simple, easy, reliable and in real-time !
Paper-Based PC-Based Controller-Based
IT systems （MES・ERP） IT systems （MES・ERP） IT systems （MES・ERP）

PLC controls the equipment.

Input the product PLC and information systems are
result data manually connected through a Gateway PC.
Easy &
no program! Direct
Real-time
Lack of data
Wrong data Highly Reliable
Gateway PC
Gateway PC
・Extra work by manual inputs ・Need to develop
・Incorrect & delayed Information communication software
・Limited information Embedded system
Operating ・Difficult to achieve real time
Instruction data collection
& ・Low reliability
Results input ・High maintenance cost
（OS version up, etc.）

Shop floor Shop floor Shop floor

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 Visibility of production equipment’s energy data
Collect energy data in real time
Construct an energy efficient system through analysis of production and
energy data
① Improve productivity while reducing energy consumption
② Reduce errors and minimizing energy loss
③ Implement high performance equipment to reduce energy usage
Production Management System
Power Management System
Database

Production
Factory Equipment and Installations
Line
Factory as a whole Each production line Each equipment
(Total Production) (Production per line) (Production per equipment)
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 Industrial automation energy solution

Availability of energy information enhances

productivity and reduces total cost

IT system (MES/ERP)

IA-IT connectivity Information

products linkage

Laser
Controller Processing
Devices PLC NC EDM Machine Robot

Shop floor
Mitsubishi Electric
CC-Link/LT
Compatible Products Measure Meter Monitor
Servo Inverter

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 Integrated automation platform
Controller & HMI Common control platform

Engineering Environment Integrated engineering environment

PLC Motion CNC HMI PLC Motion

Robot Embedded PC

Common Platform System management tool

Seamless
communication
iQ Platform
Controller
Sharing between
HMI SV・VFD Robot System DB software tools

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 Total safety solution
Safety
Level Safety PLC
（Large Scale, Complex
Safety I/O module Safety Control）
（Small Scale
Category 4 Safety Control）
SIL3
PLe

CNC
Motion controller Safety controller
（Monitoring of Safety Signal） （Mid Scale Safety Control）

Category 3
SIL2 CNC
PLd （Monitoring of Speed）

Servo, Inverter
（STO）
Scale
（I/O points）
Standalone installations,
small scale safety systems Multiple Installations and production lines, mid
(～10 points) scale safety systems (ten～hundreds points)
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 Global Partnership
① IT System
Proposal Total Solution

IBM

② Engineering

Open Network

③ Field Devices

Vision、Barcode.R
ビジョン・ﾊﾞｰｺｰﾄﾞﾘｰﾀﾞ RFID Sensor
レーザ変位センサファイバーセンサ ( sw/ curtain)
Safety(ｽｲｯﾁ/ﾗｲﾄｶｰﾃﾝ)

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 Application examples of Mitsubishi Solutions

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 Quality & operation management
Collect operating information, quality information, and tool information of
each process

Starter production line Rotor production line MES Database

Server
Winding Intermediate Attaching Assembling (Operating & quality management
Welding test Molding rotor Balancing
wire magnet system)

Quality management information,

Operating management information,
Wear of tool information, etc.
Operational Winding Welding Winding wire Molding Attaching Accuracy of Remaining unbalance
status, tool wire time etc. resistance condition etc. condition measurement amount
information, condition values etc. etc.
etc. etc.

System Magnet Bolt Accuracy Average,

branch attaching tightening of resistance Verification Accuracy Verification Verification
condition torque etc. assembly values, etc. results etc. etc. results etc. results etc.
line LAN etc. etc.
Quality analysis tool (QC tool)

Attaching Accuracy Resistance Assembling Encoder Shipping Quality

Assembling measurement test Pressure encoder test
magnet test
test department

Line monitoring
Motor assembly line Operators
Managers

Product flow Quality information Equipment operation analysis tool

Production
Production process Operating information engineering
department
MELSEC PLC Instruction information
(with IA-IT connectivity module)

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 Energy saving with visualization

Specific consumption management

Manufacturing control of all facilities
Production & Energy
Management Server Energy management
High efficiency devices

Cont Elect Product・Quality・

rical Control Cont Electrical pw Cont Electrical pw
rol Operation・Energy・ consumption
etc Alarm, error rol rol consumption
Demand

On/Off On/Off
Electric
Flow Production line Measurement Measurement
etc… Air-conditioning
Lighting controller
controller

Compressor High efficiency devices Lighting devices Power module Control module

Utilities Production facilities Lighting facilities Air-conditioning

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 Benefit of visualization

+80%
Increased through visualization and
increase in productivity
utilization of production information

+90%
Increased by referencing
increase in operating rate
real-time quality information

-50%
reduction in quality loss Reduced by zero defectiveness
with quality control

-20%
reduction energy cost Reduced through visualization
and energy management of facilities

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 Integrated common platform (Automotive)
Reduce Total Cost of Ownership
GOT1000

P/T Machining P/T Assembly Welding Painting Body Assembly

Ｃｏｍｍｏｎ Ｎｅｔｗｏｒｋ(CC-Link/IE/LT/Safety)

Reduced training Common

Common
and platform
specification and
maintenance reduces need
easy engineering
costs for spare parts

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 Traceability in the power train assembly area
Power train assembly MES ERP
Traceability in power train assembly through
information integration. All machinery reports
Machinery
their status to the MES
server automatically.
Data traceability through the status
MES-IT module automatically
reports to the
Stable operation without computers FA-IT module MES server
Eliminate unnecessary programming

Andon Picking Nut runner Sensor

Achieve
best performance
and reduce TCO

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 Thank you for your attention!

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