Mitch Tseng, Ph.D. Huawei Technologies /Tseng InfoServ, LLC

March 29-31, 2017

Rejuvenate Rejuvenate Rejuvenate Rejuvenate the Manufacturing Force with the Manufacturing Force with the Manufacturing Force with the Manufacturing Force with IIoTIIoTIIoTIIoT–––– Practical lessons learned through the MQM TestbedPractical lessons learned through the MQM TestbedPractical lessons learned through the MQM TestbedPractical lessons learned through the MQM Testbed

IIC MQM Testbed Partners:

Abstract Abstract Abstract Abstract ---- Rejuvenate the Manufacturing Force with Rejuvenate the Manufacturing Force with Rejuvenate the Manufacturing Force with Rejuvenate the Manufacturing Force with IIoTIIoTIIoTIIoT

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China has been the “World’s Factory”, especially for manufacturing labor-intensive products, for more than two decades. In recent years, when the world is moving towards Smart Manufacturing, the Chinese industry has been feeling the pinch from facing the enormous challenges of the number and the diversity of factories need to be upgraded. Although superseding the old ones with modern factories through the “green-field” approach seems to be straightforward, the excessive capital investment for demolishing the old factories and replacing them with contemporary ones has become formidable. Furthermore, workers need to be temporarily furloughed during the period of constructing the new factories can cause severe social challenges as well. As a result, in addition to simply building new modern factories, how to effectively retrofit the existing factories with new sensing, control and intelligent platform to help improve decision-making technologies developed through supporting the Industrial Internet of Thing (IIoT), will be crucial.

Manufacturing Quality Management (MQM) Testbed in Industrial Internet Consortium (IIC) is an initiative supported by Huawei, Haier, China Telecom, and CAICT (China Academy of Information and Communications Technology) with a goal to deal with the aforementioned matter.

The objective of the testbed is to create a repeatable process so as to renovate and retrofit the legacy manufacturing facilities with quality improvement as a cohesive objective measure. By managing the quality measures all through the production line and using it as the key factor to demonstrate the effectiveness of the improvement while modernizing the existing factory, the team adopted IIC’s reference architecture and constructed the testbed with advanced data collection, analysis, and process management capability. The MQM Testbed is targeted to be completed in late 2017. There have been many challenges, including unexpected limitations eventually forced the team to change the initial design. These experiences, although painful, are good lessons learned and will be beneficial to parties interested in engaging in similar activities.

Moreover, MQM is an essential building block for “Intelligent Manufacturing”, which is the core of “Made in China 2025” initiative. The initiative was kicked-off by the Chinese State Department on May 8th, 2015 with an aim to transform the conventional production systems into “Intelligent Manufacturing” systems by leveraging the technology development of ICT and IoT.

Industrial Internet Industrial Internet Industrial Internet Industrial Internet Consortium Consortium Consortium Consortium ---- IICIICIICIIC

Mission

The IIC is a global, member supported organization that promotes the accelerated growth of the Industrial Internet of Things by coordinating ecosystem initiatives to securely connect, control and integrate assets and systems of assets with people, processes and data using common architectures, interoperability and open standards to deliver transformational business and societal outcomes across industries and public infrastructure.

Launched in March 2014 by five founding members:

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The IIC is an open, neutral “sandbox” where industry, academia and

government meet to collaborate, innovate and enable.

270+ Member Organizations

Spanning 30+ Countries

www.iiconsortium.org

Organization Structure of IIC Organization Structure of IIC Organization Structure of IIC Organization Structure of IIC

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(21)

(6)

LegalWorking Group

IIC Testbeds!IIC Testbeds!IIC Testbeds!IIC Testbeds!

IIC has by far the industry’s most comprehensive testbed program (26 approved with several in the queue)

Key goals

• Ensure practical guidance

• Make impact

• Span the industry

MQM Testbed

Testbed Provides Tangible Values Testbed Provides Tangible Values Testbed Provides Tangible Values Testbed Provides Tangible Values to IIC to IIC to IIC to IIC Members Members Members Members

• Encourage teaming and ecosystem development

• Help member companies correctly apply IIC guidance

• Provide market visibility

• Lend market credibility to member companies by implying that the IIC acknowledges leadership in specific application areas

• Provide opportunity to secure proof points and partner/customer exposure for nascent technologies

• Increase the likelihood of securing government or company funding

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IndustryIndustry

IICIIC

MembersMembers

Testbed

Value

Testbed

Value

MQM Testbed: MQM Testbed: MQM Testbed: MQM Testbed: Vision, Goals, Impact, and BenefitsVision, Goals, Impact, and BenefitsVision, Goals, Impact, and BenefitsVision, Goals, Impact, and Benefits

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Objective: Develop a repeatable process to renovate and retrofit the legacy manufacturing facilities

Using Quality as Measure; Based on IIC Reference Architecture .

MQM Testbed

Policy Compliance Society Harmony

Brown vs. Green

Smarter and Greener

IndustrialBusiness

Foster Business SuccessTangible Benefits

Values

Public Funding

What is What is What is What is Manufacturing Quality Management Manufacturing Quality Management Manufacturing Quality Management Manufacturing Quality Management （（（（MQMMQMMQMMQM））））????

Manufacturing Quality Management (MQM) is an essential building block for

“Intelligent Manufacturing”, which is the core of “Made in China 2025”[Note].

The proposed MQM system is part of the 94 State approved projects to address:

• Economically - Lowering CAPEX for factory renovation

• Socially - Minimizing impacts to existing workers in the process.

A key objective is to create a repeatable process to renovate and retrofit the legacy

manufacturing facilities

• With quality improvement as an cohesive objective measure in the core process;

• With advanced data collection, analysis, and process management capability.

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[Note] The Chinese State Department kicked-off the “Made in China 2025” initiative on May 8, 2015, with an aim to transform the

conventional production systems into “Intelligent Manufacturing” systems by leveraging the technology development of ICT and IoT.

Overview: Manufacturing Quality Management TestbedOverview: Manufacturing Quality Management TestbedOverview: Manufacturing Quality Management TestbedOverview: Manufacturing Quality Management Testbed

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Collaborators :

Huawei, Haier, China Telecom, and CAICT

Market Segment:

Manufacturing quality management in home appliance industry and can be extended to other manufacturing-oriented sector.

Goal:

To establish a repeatable process and means to:

• Analyze and remodel the tooling for a manufacturing facility;

• Improve product quality through modern sensing and process control.

MQM Testbed Focus:MQM Testbed Focus:MQM Testbed Focus:MQM Testbed Focus:

Brownfield Brownfield Brownfield Brownfield AAAApproach pproach pproach pproach to Rto Rto Rto Renovating enovating enovating enovating MMMManufacturinganufacturinganufacturinganufacturing

The MQM testbed is focused on identifying a repeatable quality management

process to help renovate and modernize existing manufacturing facilities to meet

the challenges of high quality standards in the future.

Furthermore, the MQM testbed will:

• retrofit the existing manufacturing facilities with advanced technologies,

• leverage the IoT and sensory network technologies for effective data acquisition,

• employ cognitive data analysis to adaptively upgrade the manufacturing process,

• include energy efficiency and environment control into manufacturing process.

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Targeted Commercial BenefitsTargeted Commercial BenefitsTargeted Commercial BenefitsTargeted Commercial Benefits

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Customization ServiceBackward Production

Facilities Replacement

New IIoT Technologies

Production Efficiency

↑ 5%

Manpower ↓ 55%，，，， Cost ↓ 27%，，，， Productivity ↑ 15%, Customization Manpower ↓ 55%，，，， Cost ↓ 27%，，，， Productivity ↑ 15%, Customization

Production Efficiency

↑ 15%Production Efficiency

↑ 10%

Step1 Step2Step3

• Lowering the CAPEX and OPEX;

• Increasing the Production Efficiency.

The Initial Usage ScenarioThe Initial Usage ScenarioThe Initial Usage ScenarioThe Initial Usage Scenario

Decrease Defect Rate of Automatic Welding

• Current yield for automatic welding of air-conditioning

condensers is far from satisfaction;

• Control parameters are expected to be recorded and

transferred to manufacturing platform for analysis;

however, the current installment can not adequately

address the issue;

• With appropriate data analysis and process modification,

the optimal combination of the settings of the tooling can

be determined; and,

• The process can be adjusted in real-time.

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Sensors(some for

Environmental

Control)

Machines(no built-in

Sensing

capability)

Quality

Monitors(by visual

Inspection)

Challenges in Challenges in Challenges in Challenges in the Current Environmentthe Current Environmentthe Current Environmentthe Current Environment

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IoT Gateway

Factory and Production Lines

“Platform” Production Management

Data needed are not always available;Data Integrity is not guaranteed. Fault Prediction

Cannot be done

No in-depthAnalysis forQuality Management

Network

Some Statistical Data Processingbut results are not useful.

Router

Switch

DAS NAS SAN Object

User/Manager

Data Storage cannot handle the amount of data

No means to handle lossy or faulty data

Must be on-site

No RemoteManagement

Some data network deployed

in a lossy environment

Data transmission

is not reliable.

Focus on only Single pointSolution

MQM Testbed to Meet the Challenges Using the IIRAMQM Testbed to Meet the Challenges Using the IIRAMQM Testbed to Meet the Challenges Using the IIRAMQM Testbed to Meet the Challenges Using the IIRA

� The testbed utilizes the IIRA’s “Three-tier architecture pattern”

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Reference Architecture:

Sensors (e.g. Thermal

Imaging

Sensors)

Machines(e.g. Welding

Machines)

Quality

Monitors

Platform TierPlatform TierPlatform TierPlatform Tier

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� Brain-like Cognitive Platform

� cognitive analytics and soft computing

� novel learning algorithms and control protocols

� APIs

� Data Processing Platform

�computing framework: computing task scheduling and resource management

�high throughput messaging path

� Intelligent Storage Platform

� Data Aware Engine

� Content Analytics

� Unified Storage Engine

Image Audio Document

Unified Storage Interface

Image Content

Analysis

Audio Content

Analysis

Document

Content Analysis

Content Analytics

hardware hardware hardware

hot warm cold

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IoT Gateway

Edge Tier Platform Tier Enterprise Tier

Intelligent Storage Platform

Analytical Platform(Cognitive Analytics plus Third-Party Solutions)

Fault Prediction

Quality Management

Network

Data Processing Platform

Router

Switch

DAS NAS SAN Object

User/Manager

https

Sensors (e.g. Thermal

Imaging

Sensors)

Machines(e.g. Welding

Machines)

Quality

Monitors

Sensory Network

(With In-House or Third-Party Solutions)

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2

3

4

5

6

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Firewall

MQM Testbed Security ConsiderationsMQM Testbed Security ConsiderationsMQM Testbed Security ConsiderationsMQM Testbed Security Considerations

Threat Model Reviewed with the Security Working Group.

This will be considered in more detail during the Testbed Design Phase.

Deployment & FundingDeployment & FundingDeployment & FundingDeployment & Funding

DEPLOYMENT

• The deployment and operation of this testbed will be in China, initially.

• The physical components will be installed on premise in the manufacturing or maintenance sites. Meanwhile, software can be deployed on premise or through the cloud, depending on the requirements.

• Access control and management are limited to the participants.

FUNDING

• Funding for the testbed will be from the participating companies.

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Testbed Innovation and ExperimentationTestbed Innovation and ExperimentationTestbed Innovation and ExperimentationTestbed Innovation and Experimentation

Lesson/Challenges learned from Current Phase:

1. Focusing on Analytic Engine

• Proven to be effective (help improve the yield rate)

• Under usage of the Cognitive Computing Platform

2. Retrofitting the sensing module

• Challenges of integrating the sensors

• Work with the vendors of the existing sensing units

3. Accommodating the existing operations

• The old process may not fit for the future.

• Need new thinking in business planning.

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From 36,000 feet, every Testbed looks alike!• Sensory Network, Analytic, Management, etc.

• “The devil is in the details!”• You won’t even notice it until it hits you!

Where it might fail …

Challenges: Technical, Business, Field, Evolution …

Testbed Outputs and ResultsTestbed Outputs and ResultsTestbed Outputs and ResultsTestbed Outputs and Results

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MQM Testbed Results and Key Findings: 1. Phase 1 (H1/2016): Requirements Completed.

Discovered that sensing module for welding section

not practical.

2. Phase 2 (H2/2016): Refocus on “Noise Detection”.

Testbed Design Completed.

3. Phase 3 (H1/2017): Integrating the Noise Detection

Modules (On going…)

4. Phase 4 (H2/2017): Testbed Deployment and

Validation (On going …)

Lesson Learned:• When dealing with a field issue, listen carefully to

establish the “common ground” first.

• Recognize the IT/OT “knowledge gap”!

• A WeChat Group for key personnel was

established to exchange information.

• Do not underestimate the difference between the

field deployment and in the Lab.

• You won’t even notice it until it hits you!

• “Human Factor” is much harder than Tech.

MQM 2.0:

In addition to retrofitting the current processes, we will

look into transition the old process into the new ones

(“overhaul” to rebuild the manufacturing process).

Open up the opportunities for further collaborations

with IIC Members.

Importance to IIC and Ecosystem ContributionsImportance to IIC and Ecosystem ContributionsImportance to IIC and Ecosystem ContributionsImportance to IIC and Ecosystem Contributions

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When the Rubber Hits the Road …Facilitate collaboration among IIC Members

Real Challenge (not proto type, Deal with real world Scenarios),

Real Customer (Not “If I build it, they will come!”),

High risk, but high learning/gain

As promised, the team is ready to work with other IIC Members to jointly exploit the Testbed:

• Partners need Edge Computing Platform (IoT Gateway, Agile Controller and Cognitive Computing).

• The cognitive computing could deal with text, voice, picture and video input sources.

• Field System Integration and Operation Refinement (OT Specialists)

• Business Planning and Event Processing Platform.

• Specialized sensors and Sensory Subsystems.

Calling all hands … (Collaboration for the MQM Testbed)

Collaboration among ALL IIC Members!

MQM

Thank YouThank YouThank YouThank You

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