제조를 제조하다

4차산업혁명과 스마트팩토리

IoT 와 머신러닝 기반의 스마트팩토리(Importance of Data Collection and Analysis)

4th Industrial Revolution

▪ 저성장, 변동성 확대

▪ 중국경제 리스크 확대

▪ 저유가 시대

▪ 산업경쟁 구도 심화

CHANGE

Manufacturing

▪ 가치사슬의 파괴 –기본 프로세스의 파괴▪ 규모 경제의무력화▪ 고객의 Needs 변화 (Personalization, Custom-made)▪ 혁신의 가속화

노동력감소 인건비상승생산경쟁력

하락설비노후

시장과열에따른비용절감의압박

SMART Age

제조업의 중요도&비중

1980 1984 1988 1992 1996 2000 2004 2008 2012

Manufacturing vs. Service(Percent of GDP)Source : International Monetary Fund

10

15

20

Manufacturing

Services

Farming

✓ Manufacturing has been going through a difficult time

‘2006 Hi-Tech Strategy 2020

‘2011 Industrie 4.0 Smart FactoryManufacturing + IT

OT + IT

Smart Factory

Smart Factory

Current of the Global

Smart FactoryFactory Automation

NOT AUTOMATION !!!

The market is being changed rapidly

My own productPurchase cost with pleasure

Smart Age Customizer, Personalization

동일제품, 대량생산, 대량판매

Hit / Fix / Large

다양제품, 소량생산, 소량판매

Needs / Fluid / Few

Smart, Web, Customize, Personalization

Individual Customers

Big Data Analysis Development

Production Logistics

Manufacturing InnovationProduct Innovation + PSS (Product service system)

제조산업영향

Life/타산업영향

Smart Factory

Products Development > Production > ServicesA factory where all phases are optimized

엔진

플랫폼

판매서비스

범퍼

기타

제조혁신프로세스

고객

반응

설계

생산

생산

설계

엔진

제품개발제품설계

조립범퍼

기타

판매서비스 고객

기본의제조생산프로세스

발주

발주

발주

납품

납품

납품

시뮬레이션

대량생산중심의효율성 ???

➢ 생산성

➢ 가동율

➢ 인건비

➢ 경쟁력

대량생산중심의효율성???

The market is being changed rapidly

My own productPurchase cost with pleasure

고객(시장)의변화에대응이중심

Products Development > Production > ServicesA factory where all phases are optimized

• Environmental element

• Operator&Worker’s

• Accident prevention

• Electric management

• Operating costs

• Cost of production

• Facility abnormality

• machine Pre-check

• Predictive maintenance

• Terms of production

• Production machinery

• Operating variable

• Customer analysis

• Production plan

• Inventory & Logistics

Production management Quality control Facility management Energy conservationEnvironmental & Safety

management

1 2 3 4 5

Smart Factory

High Cost & Long Time

Data

Manufacturing Industry StructureSource : Machina Research STRACORP

Large manufacturing

factory0.6%

17.8%

(Kor 96%)about 36 million

Medium manufacturing

factory

81.6%

Manualy production Counting by a worker

History management

Unformatted Process

Operational Traning Obsolescence of equipment

Small & Medium manufacturing industry

의사결정(Decision making)

What is the problem? What will happen?

?

?

??

?

DATA

Information

Decision

GOAL

Quality

Cost

Delivery Time

Flexibility

제조공장을효율적운영은

얼마나빠르고, 정확한의사결정(판단)이핵심

이를위해선첫시작이 DATA 수집과분석(상황판단)에있다.

IoTSensor

Big-Data

M/L, AI

NetworkVisualization

oneM2M MQTT

OT

AutomaticPLC

Control

Gateway

SCADA

IT

ERP

MES

PMS

SCM

QMS

(Information Technology)

Further Phase

01

Network

Connection

Data

Collection

02

Real-Time

Visibility

03

Analysis

of Data and

Production

Precess

04

Production

Optimization

05

Future Plan

Automated

Control

06

Sensor

Installation

The method of DATA Collecting The method of DATA Analyzing Monitoring andImproving Product

ion Precess

LEVEL

0

DATA 5V

• 데이터의 양 (Volume)

• 생성 주기(Velocity)

• 종류(Variety)

• 정확성(Veracity)

• 가치(Value)

Siemens Amberg Smart Factory(지멘스 암베르크 EWA)

일 실시간 Data건수

5,000만건

Siemens Amberg Smart Factory GE (General Electric)

일 실시간 Data량

520GB

1. 원료 2. 발포 3. 숙성 4. 성형 5. 건조 6. 절단 7. 출고

Machines, Method(생산/품질/공정 관리)

생산 및 작업조건, 설비가동 데이터

생산공장

보일러실

PAC Platform

(Personal Performance Analysis&Control)

작업 데이터 + 설비운영 데이터

건조가공

Smart Factory TPM

(Total Performance Management)

DATA 수집 영역 : 품질경영 4대 요소 4M

•작업자(Man) •설비(Machine) •생산방법(Method) •재료(Material)

ERP, MES, PLM, SCM, CPS….

수기노트 PLC, ODL Real-Time Data

Without changing existing facilities

Easy to set up Affordable Without training

on Big data

AI

IIoTIndustrial Internet of Things

OT ITERP, MES,

PLM, SCM, CPSOther System….

Application

IIoTIndustrial Internet of Things

IIoTIndustrial Internet of Things

PLC, DOM, SCADA, DL …

What? 1. Apply System : IoT is Easy to Set up and Simple

Sending

Production

data via

3G/WiFi

DataAnalysis

Real-timeMonitoring

Managingthe production

and quality

WIM-X

Smart DeviceUser

Cloud Platform

Data Analysis

WICON IoT Device

wiconwicon

wicon

What? 2. Flexible : As-is manufacturing plants are

difficult to change their processes.

M/L & AiMachine Learning & Artificial intelligence

Ai

M/L를통해 (상황을) 인식하고판단하는기술

M/L

Data를 통해 상황을 학습하는 기술

M/L & AiMachine Learning & Artificial intelligence

M/L & AiMachine Learning & Artificial intelligence

1950 앨런튜링, 1956 : Ai 단어등장

[1. 수집된 시계열 데이터] [2. 데이터 전처리 샘플링] [3. 데이터 전처리 분석] [4. 오작동 데이터 분석]

[5. 유효데이터 분석 및 추출] [6. Standard 데이터 학습] [7. Standard 데이터 학습] [8. 오작동 및 불량 기준 생성]

➢ Between Sensors

➢ Between Facilities

➢Facility Malfunctioning Analysis (predictive maintenance)

➢Facility Status Analysis

➢Production Condition and Operation Status

127

!

여기에빵을만드는전기오븐이있습니다.

현재변화에대응하기위해서는빵만드는기계가아니라

맛있는빵만드는방법이필요합니다.

Copyright ⓒulalaLAB, Inc. (www.ulalaLAB.com)

ulalaLAB Inc.

No.614, 6F, 11-41, Simin-daero 327beon-gil,

Dongan-gu, Anyang-si, Gyeonggi-do, Korea

+82-2-873-0010 mail@ulalaLAB.com

Thank You

감지[ Sense ]

판단[ Decision ]

수행[ Actuator ]

품질경영을위한 4M 요소의이벤트를감지하고유의미한

Data를 관리하는 기능

감지된 Data를 의거 의사결정(작업 지시 및 실행 등)

판단 결과가생산 현장에반영되어 수행되는기능

Smart FactoryFunctional 3element

(스마트팩토리 기능적 3요소)

⑨ Cloud Platform

Smart FactoryFunctional 3element(스마트팩토리 기능적 3요소)

&

IoT Technology(핵심기술)

② DATA

③ Network

④ Big-Data⑤ Analysis & M/L⑥ Visualization

⑦ ApplicationSmart Tech

⑧ ControlIntelligence Tech

감지[ Sense ]

판단[ Decision ]

수행[ Actuator ]

① Sensor