1. Towards the CYBER FACTORY versalog Colin Hales Agents Lab/Vic Fri April 26 2002 colin@versalog.com.au

2. versalog Overview Evolution of automation Evolution of automation Evolution of technology in factory automation Evolution of technology in factory automation Economic and logistical imperatives driving change Economic and logistical imperatives driving change Social - the role of humans in factories over the years and in the future. Social - the role of humans in factories over the years and in the future. Holonics Holonics Use of intelligent agents (max payback) in Holonics Use of intelligent agents (max payback) in Holonics

3. versalog Manufacturing Paradigm Shifts 19002000 Craft Sum of All Manufacturing types 1980s Mass Production Options ++ Mass Customisation 1910 Different philosophies for manufacturing are needed mass- customized, low-volume, high-mix mass-produced, high-volume, low-mix

4. versalog $$$$$$$ Software & Services Drive Total Automation Business for Process Industries The worldwide market for Automation Products and Services for Process Industries, over $44 billion in 2001, is expected to grow at the compounded annual growth rate of just over 5% over the next five years. Without question, growth will be driven by software and services while traditional hardware- based markets experience below average growth. Source: http://www.arcweb.com/arcweb/newsmag/auto55_autoproc.asp

5. versalog - The Evolution of Control Technology- 10 8 10 9 10 7 10 6 10 5 10 4 10 2 10 1 10 0 10 3 1930 1940195019601970198019902000 Functionality Increases Solid State Control Relay PLC Hierarchical PLC Structure Distributed HOLONIC Granular H/W

6. versalog - The Evolution of Control Technology- Euphoria Perception Valley of Cynicism Gradual Adoption Americans….. Australians Time FAD STOPPER

7. versalog - When standing still is falling behind………………: - Forces Driving Change Change is by quantum leap Change is by quantum leap Competitive advantage through looking at your customers customer. Competitive advantage through looking at your customers customer. Machines that make the machines are automated Machines that make the machines are automated

8. versalog State of Technology Imagine a world with 25 Bill Gates Imagine a world with 25 Bill Gates Supplier stranglehold game Supplier stranglehold game

9. versalog State of Technology But it got better: Open Systems But it got better: Open Systems Lags PC world by a reducing time Lags PC world by a reducing time

10. versalog State of Technology Issues:SensorsCommunications Programming Languages HMI/SCADA Operating Systems BUS standards CPU

11. versalog State of Technology Issues: Stabilisation on open standards is occurring, but the old stranglehold persists for political reasons. I want 1 and 1 only BUM to KICK.

12. versalog State of Technology Buying Habits The ONE STOP SHOP

13. versalog State of Technology Highly Parallel Highly Parallel The full circle…. Centralised/ Monolithic Centralised/ Monolithic Highly serial De-Centralised De-CentralisedParallel/serial Granular GranularParallel

14. versalog - When standing still is falling behind………………: - Forces Driving Change Technology/new materials. Technology/new materials. GLOBALISATION GLOBALISATION Time to market Time to market Mass customisation Mass customisation Internet (Browsers/TCP/IP) Internet (Browsers/TCP/IP) New semiconductor technologies New semiconductor technologies Embedded Windows Embedded Windows Microsoft active involvement – OPC Microsoft active involvement – OPC

15. versalog - When standing still is falling behind………………: - Forces Driving Change INTEGRATION of business systems and the plant floor like never before. INTEGRATION of business systems and the plant floor like never before. Web Based implementations of traditional SCADA Web Based implementations of traditional SCADA WEB Based Industrial Devices/Processors WEB Based Industrial Devices/Processors COMMS: Foundation Fieldbus (finally) COMMS: Foundation Fieldbus (finally) PROCESSORS: PC Based control (Windows CE) PROCESSORS: PC Based control (Windows CE) Granular Distributed Control Systems Granular Distributed Control Systems DCS Functions on Traditional PLC/Soft PLC DCS Functions on Traditional PLC/Soft PLC REGULATORY: The biological revolution….pharma/drugs REGULATORY: The biological revolution….pharma/drugs

16. versalog Traditional Manufacturing Computing Plant Floor Admin Engineering Maintenance OLD XYZ Co. Marketing/Sale s

17. versalog Holonics- 101 Sub- contractor Holarchy Sub Contract Dialogue Sub- contractor Subcontractor Worker Task Assignments Hierarchy BOSS Worker

18. versalog Holonics- 101 – in business New XYZ Co. Admin, Marketing,Sales, Engineering, Finance, Maintenance, Plant Floor, Computing, Warehousing New ABC Co Eg outsourced Computing.. New MNO Co Eg outsourced Maint. New PQ R Co Eg Bankin g etc Co Customer Co Team Based Team Based End Customer Need Focussed End Customer Need Focussed Producer/Consumer Nested Producer/Consumer Nested Time invariant Time invariant Space invariant Space invariant

19. versalog Peoples Whole View of Business will change It becomes, in the limit: 1)a set of managed material/service flows that converge on a customer in that it is pulled into existence by demand. 2)A flow of money in the opposite direction.

20. versalog Holonics- 101 – in business Holonics is happening in business practice, even though they dont know it. Holonics is happening in business practice, even though they dont know it. This is a useful indicator of imminence of readiness for Agents This is a useful indicator of imminence of readiness for Agents Automation systems driven by manufacturing demand as created ever more directly by the customer base. Automation systems driven by manufacturing demand as created ever more directly by the customer base.

21. versalog Agents in Manufacturing Managing product life cycle in an environment of continual change Managing product life cycle in an environment of continual change Performance Monitoring and Analysis Performance Monitoring and Analysis Decision support Decision support Knowledge Management Knowledge Management Procedure Management Procedure Management Fault Detection and Diagnosis Fault Detection and Diagnosis Alarm Management Alarm Management Condition Monitoring and Predictive Maintenance Condition Monitoring and Predictive Maintenance Inventory Management Inventory Management

22. versalog Agents in Manufacturing Supply Chain Management Supply Chain Management Training Training ERP/MES, SP95, SP81, SP88, IEC61139 ERP/MES, SP95, SP81, SP88, IEC61139 Scada setup Scada setup Calibration Calibration Quality Information Systems Quality Information Systems Statistical Analysis Statistical Analysis Production Tracking Production Tracking Automated Data Management Automated Data Management Resource Management Resource Management Advanced Scheduling Advanced Scheduling

23. versalog Agents in Manufacturing This is the fully holonic dream. Expert agents negotiate to run the plant optimally according to orders. Humans intervene to make critical decisions, teach, navigate change and get involved in diagnostics and repair.

24. versalog Agents in Manufacturing So what to do first? So what to do first? First a little structure is needed MRP MES Cell Machine Increasing Cost of Change Increasing Demand for Change Multi Site

25. versalog Agents in Manufacturing So what to do first? So what to do first? First a little structure is needed MRP MES Cell Machine My Interest is here

26. versalog Agents in Manufacturing Basic Agent Scope of Works Basic Agent Scope of Works Takes over Auto control of plant Learns how to run the plant. Humans teach it. Learns how to run the plant. Humans teach it. Eliminate programming. Learn IEC61131, SP8 Eliminate programming. Learn IEC61131, SP8 Diagnostics assistance Diagnostics assistance Deals with local production scheduling Deals with local production scheduling Works with humans for manual operations Works with humans for manual operations Inhabits plant, 24/7

27. versalog Agents in Manufacturing Why is it possible….? Why is it possible….? ONTOLOGIES require much less effort to formalise, they are highly specified already although indirectly.

28. versalog The Human Factor My observations: Change is a shock in that it changes the type of the work done and the number of people. Displacement occurs. It will be the same with Agents.

29. versalog What Colin Wants Dumb Hardware Command Based Software Rule Based Software Autonomy Co- operation Intelligence Reasoning Systems Relay/I/O points Programmable Devices Learning Systems Holonic Controls Biological/Life forms CH

30. versalog The Cyber Factory The manufacturing pyramid is run by agents whose biological based Avatars call humans as needed. Of course, nano technology will probably render it all obsolete, but……. I think theres still a long way to go.

31. versalog The Cyber Factory Thats All, Folk. Thanks……..