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It took nearly a year for SAP and Shenyang Institute of Automation, Chinese Academy of Sciences, to jointly develop the first demonstration line of Industry 4.0 and at the end of 2015 at the World Internet Conference. First time out.
From a software-defined production line where e-commerce and WeChat portals are directly connected to the back-end, from the local industrial internet to cross- ocean cloud services and big data processing, China is now at the forefront of new industrial practices.
In the future, the intelligent manufacturing scenario is exemplified by a customized automobile model. The industrial 4.0 demonstration production line developed by Shen Zisuo and SAP China Research Institute shows a complete picture of the smart manufacturing scenario in the future.
This smart manufacturing demonstration production line has officially settled in Shenyang Institute of Technology, Shenyang Institute of Technology. It is an 8 meter by 8 meter simulation production workshop that includes a number of devices – five robotic arms, two automatic guided vehicles, and 100 Taiwan WIA-FA industrial wireless equipment.
Ordinary consumers can place orders through the e-commerce website, mobile phone user interface or directly on the WeChat public account built on the SAP E-Business Suite Hybris, and can choose different models and body colors according to their preferences.
After the order is generated, the relevant information is transmitted to the ERP system of the simulated vehicle model manufacturing company. The ERP system will complete preparations for production materials, production plans, and production costs accordingly based on the current order status.
When the ERP system completes the production plan, the corresponding work order will be transferred to the factory's MES production and execution system, and delivered to the factory's production line through the MES.
The MES automatically selects the work order with the highest priority, and after the factory production line receives the production work order information, it will send a product tray and be equipped with an RFID tag. All information related to this product is recorded in this unique RFID tag. The production workstations in each process interact with RFID tags.
The entire demonstration line has a total of 7 processes, involving 6 production stations, and 2 mobile backup production stations. When the production line is full, it can automatically call the mobile standby production station to enter the production system. When the production capacity is idle, the standby production station will be removed from the production system to achieve the effect of energy conservation and emission reduction.
Consumers can watch the entire production process remotely on websites, mobile terminals, and WeChat. Factory managers and engineers can also observe the working status of the entire production line and order operations on the iPad, and relevant data are also provided to the upstream and downstream supply chains in real time. To ensure the supply of production materials.
If the equipment fails, the maintenance personnel use a mobile phone to scan the QR code of each production equipment and directly eject the 3D maintenance instructions. By connecting the smart glasses to Skype, they can consult with the remote technical experts.
The three key technologies This industrial 4.0 demonstration production line demonstrates which key technologies? According to Li Ruicheng, Director of SAP China Research Institute, the demonstration production line has realized the basic concept of Industry 4.0, including personal orders, flexible production, and three major Integration, industrial cloud, big data and so on, especially the integrated cloud services of the production line are actually located in Singapore, truly embodying the global integrated intelligent manufacturing.
According to Zeng Peng, director of the Industrial Control Network and System Research Division of Shen Zisuo, the biggest feature of the entire demonstration production line is software-defined production, which is the so-called flexible production.
The discrete manufacturing industry nowadays has more and more personalized user needs. This demand for personalized configuration has brought great challenges to the back-end production and manufacturing links. With traditional rigid production, once the production line is installed, it is difficult to change.
In addition, the life cycle of many products is getting shorter and shorter. The upgrading and transformation of traditional rigid production lines takes time and effort, and the speed of production line lags far behind the speed of product updates.
In order to solve this problem, SAP and Shen Zi together, first of all, the vertical integration of information and data for the traditional factory information system.
The ERP resource management system, MES manufacturing execution system, PLC production control system (including industrial robots, etc.) and HANA big data processing platform from top to bottom were layered, achieving better data between each layer. Information interaction improves the efficiency of information transmission at all levels of the plant.
Secondly, from product ordering, production planning, to material preparation, and production line adjustment, the entire process is mapped into a virtual information space, and the entire manufacturing process from the user end to the production end is reconstructed in the virtual information space.
PLC programmable devices, sensors, controllers, or industrial robots on the production line are abstracted into virtual models in the information space. Information interactions and interactions between virtual models and physical devices are performed.
In this way, the original adjustment of the production line that needs to be manually configured allows rapid system reconstruction through the virtual information space, and then automates the configuration of parameters into physical devices, dramatically shortening the cycle of changes in the production line.
In the process of information exchange between the virtual information space and the real world, an industrial Internet that can perform high-speed, low-latency, high-availability, high-concurrency, and anti-jamming is required.
The industrial wireless network technology specification that Shen Zi took the lead in research and development was WIA-FA, the only IEC (International Electrotechnical Organization) wireless technology international standard for high-speed automatic control applications in factories. Shen Zi-based WIF-FA achieves high-speed wireless acquisition of demonstration production line information and data, and maintains latency within 10 milliseconds, which is superior to similar products of foreign companies.
Third, the data of the production equipment was transmitted to the SAP HANA cloud service center in Singapore in real time, and the equipment was diagnosed and real-time predicted through local big data processing.
Based on data monitoring on the production line and the establishment of various algorithms on the cloud service platform, it is possible to predict the time of failure, location of failure, and type of failure of the equipment, greatly reducing the downtime of the production line and extending the life cycle of the equipment.
At the end of January 2016, SAP China Research Institute and Shenyang University of Chinese Academy of Sciences Shen Zi signed a cooperation agreement again to further expand the scope of the intelligent manufacturing demonstration production line, including the product digital collaborative design, production and maintenance of the entire process, including the full implementation of Industry 4.0 The three major integrations of the company's internal vertical, horizontal industrial chain, and end-to-end product life cycle, and the corresponding results in the form of solutions for the manufacturing company.
Now, smart manufacturing is not the future but the future that is happening.
For the fourth industrial revolution, the entire industry and the information industry community had full discussions in 2015. In particular, with the rise of e-commerce and WeChat and other super-level mobile application portals in the past two years, a new intelligent manufacturing chain that can meet the individual needs of users and consumers and connect the user's end to the manufacturing end is being formed.