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Charles Wu
AIM Center, TECO E&M Co., LTD
Digital Transformation of Traditional Factory Using IoT Technologies
1
智動化暨生產技術中心
MESMHM
ERP
Factory
Automation
History of TECO’s Intelligent Manufacturing
in Chun-Li, Taiwan
Production 4.0Production 3.0Production 2.0Production 1.0
2015200119911979 2017
1979Chun-Li Factory
Established
- CNC implement- Line Automation- Efficiency/Quality - Mass production
ERP/MESIntegration fromSoftware Deploy
Mass Production Mass Customization
智動化暨生產技術中心
Structure of TECO’s Intelligent factory
ConsumerService
Provider
Manufacturing
Collaboration
E-Commerce
Machine CloudSupplier
Quality
Operator
5
2
4
EMS
MHM
IntelligenceManufacturing
Machine CloudQuality & Maintenance
integration
B2B e-commerceCustomer pull process
ERP & MESVertical integration SOP,
Manufacturing Management
M2MCommunication
M. CollaborationOpen information
Resource prediction
3
1
1
3
SCADA
MES
ERP
Machines
智動化暨生產技術中心
SAP ERP
SAP MES
Reports Management
SHOP FLOOR CONTROL SYSTEM
Coding control
(Logistic)
Quality control
(Big data)
Real time
BulletinMCS SYSTEM
IN-LINE CONTROL SYSTEMMuti-AGV
CONTROL System
Gateway
Conveyor VisionRobot
Main Machines Auxiliaries Safety CTL.
AGV Rout
Exchange port
Intermediate
Stocks
Robot cell ports
Copper wire
Intelligent Manufacturing of Stator Shop Floor
(Demo site) Intense use of sensors、RFID
& 1D/2D/3D vision、
Robot/AGV& fiber network for
factory automation。
Direct Link among
machines to ERP/MES
- Auto work assignment、
working time report
- Real time recipe check
- Tool check & process
data collection
- Quality and process
trace back ability
- No paper environment
- IoT & Big data ready
Sh
op
floo
r lev
el
Facto
ry le
ve
l
智動化暨生產技術中心
Existing Equipment
TECO MHM Solution
LPWAN_LoRa Solution
NewEquipment
Winding Center as a
Demo Line
Spread to other
processes
Solutions of existing Equipment/Old Machines
ConsumerService
Provider
SCADA
MES
ERP
Manufacturing
Collaboration
E-Commerce
PasS
(Edge computing)
Manufacturer
Quality
Operator
4
3
5
2
3
Machines
45
5
Supplier1
MHM
LoRa
智動化暨生產技術中心
Basic Scheme of TECO’s solution
6
Ref. Advantech IoT structure.
TECO LoRa Module
(Machine Status)
TECO MhM Module
(Maintenance)
智動化暨生產技術中心
LPWAN_LoRa
7
Tiny Server
智動化暨生產技術中心
Data collection using LPWAN (LoRa)
8
1.Status
Start、Uptime、idle
2.Process
Count、Speed
3.Environment
Temp、Humid、pressure
4.Maintenance
Downtime、Abnormal
Utilization rate
Capacity, availability
Environment, parameter
MTBF, Prediction
MhM: Application Structure Diagram
9 All remote operations are managed by Private Cloud, to protect operation privacy.
WiFi / 3G / 4G
Internet
Motor
Switchgear
IoT
Gateway
Sensors
異
常
:
Smart Phone with App
Existing SCADA
Machine Health management System
(MHm)
Broadband
Router
RS485
(Industry
Standard)
1
0
Sensors Product Series : Temperature
Analog
Magnet
USB
Stick-on
11
Sensors Product Series : Vibration
Wired
RS485
Screw-down type Magnetic Suck-on type Magnetic Suck-on type
Wired
RS485
USB
RS485
All with integrated transducer
12
4 x USB recepicles
for USB inputs
Built-in WiFi for
WiFi input/output
IoT (Internet of Things) Gateway : AG-300U
Current
Voltage
KW (Consumption)
Vibration
Temperature
RPM
Torque
13
What to manage
Machine Health Vitals
Protection Relay (OV, OC, UV,
GF…..)
Thermal Image
Air Analysis
All Sensors/detectors ever used in
SGR industry
Smart Phone APP Display
14
MHm Software Display (server-based)
15
MHm Software Display (server-based)
16
17
Vibration Temperature
MHm Software Display (server-based)
18
Just plug the gauges and the mobile power pack to the Gateway and play.
All-Smart Portable
智動化暨生產技術中心
Application of IoT technology to high-
efficiency factories
19
Prediction and symptom managementPrinciple:No downtime、No defect
Method:Big data、AI technology
Target:Minimize accidental, continuous defect
Focus Management
Principle :分析與分層後的信息於當地實物確認
Method:Process automation, Data visualization
Target:Compression the load of daily work stream
Source Improvement
Principle:Real time confirm the operation and
improvement of the factory
Method:Big data、CPS
Target:Speed up of value concretization
Co-Creation Improvement
Principle:Cross business and national boundaries
Method:Big data、CPS
Target:Speed-up of improvement and innovation
Key Machines
Real time monitoring
Manufacturing
management
KPI
IoT
Platform
Thank You For Your Listening!
Charles Wu
AIM Center, TECO E&M Co., LTD