Sensor & Data Driven Smart Factory Solution

For Small, Medium & Large Enterprise

Manufacturers

ulalalab

Learn:

PATTERN

DETECTION

AUTOMATED

DISCOVERY

Predict:

MACHINE

LEARNING

PREDICTIVE

MODELING

Adapt:

REAL TIME

PRESCRIPTION

ADAPT

PROCESSES

INSTRUCTIONS

INTELLIGENCE

OPTIMAZATIONS

DATA STREAMS

Learn from the Past Change the Future

Machine Learning and Big Data Analysis

Temperature

Humidity

Vibration1

Vibration2

Current

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PREVENTIVE PREDICTIVE OPERATOR CARE RUN TO FAILURE

Certain Death

High RiskLow Risk

( Source: Ricky Smith, Allied Reliability )

Stage 1.Approx 10%~20%

Remaining life

Stage 2.5%~10%

Remaining lifeStage 3.

1%~5% of Remaining life

Stage 4.Remaining lLifeone hour to 1%

FailureInduced

UltrasonicEnergy

Detected Vibration AnalysisFault Detection

Oil AnalysisDetected

Temperature Rise

Audible Noise

Too Hot Touch

MechanicallyLoose

CatastrophicFailure

WITHPRECISION

MAINTENANCE

Predictive Maintenance

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Technologies

Vibration Monitoring/Analysis O O O O

Lubricant, Fuel Analysis O O O O O

Wear Particle Analysis O O O O

Bearing, Temperature/Analysis O O O O

Performance Monitoring O O O O O O

Ultrasonic Noise Detection O O O O O O O

Ultrasonic Flow O O O O

Infrared Thermography O O O O O O O O O O

Non-destructive Testing (Thickness) O O O

Visual Inspection O O O O O O O O O O O

Insulation Resistance O O O O O

Motor Current Signature Analysis O

Motor Circuit Analysis O O O

Polarization Index O O O

Electrical Monitoring O O

Pu

mp

s

Ele

ctr

ic

mo

tos

Die

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l

Ge

ne

rato

rs

Co

nd

en

se

rs

He

avy

Eq

uip

me

nt

Cir

cu

it

Bre

ak

ers

Va

lve

s

He

at

Ex

ch

an

ge

rs

Ele

ctr

ical

Sys

tem

s

Tra

nsfo

rme

rs

Th

an

ks

Pip

ing

Ap

pli

cati

on

s

Predictive Maintenance

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Tool Base Condition Examination

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Temperature Sensor

Vibration Sensor

Traditional and Outdated EquipmentRequire Performance and Condition

Monitoring

Existing Monitoring Tools areExpensive and Bulky

ulalalab

CTCT

wicon

Current

Temperature

Vibration

wicon

Other Sensors

WIM-X

MACHINE - Health and Condition Monitoring

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Affordable and Easy to Deploy Performance and Condition

Monitoring Solution

Remote and Real-TimeMonitoring

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Time

Analog Data

• Vibration

• Current

• Temperature

START END

Value

Digital Data

• Air Valve

• Proximity

• Counter

Machine Learning - Status Analysis

1 Cycle

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Correlation Analysis

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RMS Velocity Vibration Severity Standards(ISO10816)

Machine Class-ISmall

Machines

Class-IIMedium

Machines

Class-IIILarge Rigid

Foundation

Class-IVLarge Soft

FoundationVrms(in/s) Vrms(mm/s)

0.01 0.28

Good

(Start)

0.02 0.45

0.03 0.71

0.04 1.12

0.07 1.80

0.11 2.80

0.18 4.50SatisFactory

(Long Run)0.28 7.10

0.44 11.2UnsatisFactory

(Alert)0.70 18.0

0.71 28.0Unacceptable

(Danger)1.10 45.0

Capacitance 15kW(20hp) 75kW(100hp) 300kW(400hp) …+

±0.25

Machine Type Pump Electric Motor Heavy Machine Large Machine

Predictive Maintenance

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Solutions ulalaLAB, Inc.

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Simple and Easy to implement

DataAnalysis

Managingthe productionand quality

IoT Device WIM-X

Smart DeviceUser

Cloud Platform

Data Analysis

wiconwicon

wicon

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Real-timeMonitoring

Sending

Production

data via3G/WiFi

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wicon

Internet/CellularGatewaySensors Cloud MonitoringInternet/Cellular

WICON

GW Device

WIM-X

Cloud PlatformSensors

WIM-X

N-Screen

3G/LTE

Ethernet

WiFi

3G/LTE

Ethernet

WiFi

Window Browser

iOS/Android

Analog Input

Digital Input

WimFactory Solutions

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Base Bracket

Communication Module

I/O Interface Module

2xLED Indicator

System Reset

Sensor Socket

DC Power Input

Div. Spec.

WiFi 802.11b/g/n

BLE 2.4 GHz RF

Battery Li-Polymer, 3.7V 2050mA

Module Ext Connector 20Pin, GPIO, UART

LED Comm Power, Communication, Check

Environment - 30 ~ + 80°C

WimFactory IoT Device

Stackable Bus

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WIF(V2.0)

WICON MAIN BLE B/D

WICON MULTI M

WIC

ON

-CO

M-B

D V

1.0

WICON WiFiWICON MAIN(2AI,2DIO)WICON Multi(485/232/I2C,SPI)

WimFactory IoT Device

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DATA communication(485, 232, I2C, SPI)

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Features

• IP67 Level

• Ethernet to WiFi

• Modbus/TCP

WimFactory IoT Device (AtlasCopco Korea ODM)

Specifications

• Quad Cortex A53 1.2GHz

• 1GB SDRAM

• 32GB Micro SD

• DC 5V / 2A

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WimFactory IP67 Class Vibration Sensor

Six-Axis (Gyro+Accelerometer)

MEMS Motion Sensor Devices

And Temperature Sensor

wicon

MPU

GYRO

ACCEL

DM

P

FIF

O I2C

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Smart Factory Total Administration Platform WIM-X

Real-time Monitoring of Production Condition

Setting the Safe / Warning / Danger Zone

Weekly / Monthly / Quarterly Status Report on Operation

Through Big data analysis and Industrial AI

Dash Board

Notification service about malfunctions

Analysis Report

Malfunctioning Prediction

WimFactory Service Platform

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Data Analytics Engine Rules, Event Machine Learning

Application Platforn

Data management SystemAPI

Production Data, Data Bank

(RAW Data, Data Source)

Application Service, Dash-Board, Web, APP

Monitoring System, Service

Network Communication

(WiFi, 3G, LTE, Ethernet)

Physical Facilities

IoT Sensor Network

(AI, DI, RS232/485, I2C)

Other System

(ERP, MES…)

Smart & Multi Devices

CL

OU

DF

AC

TO

RY

Core Value and Providing Service of WimFactory

US

ER

INT

ER

NE

T

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Cloud Service Platform WIM-X DashBoard - SaaS

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Authentication

Authorization

Accounting

IoT Security(CoAP over DTLS, MQTT over TLS) SSL VPN Secure Channel

AAA

ID, Password

(USB Token)PLC/RTU or Sensor

Secure Booting(OS)

Secure Bootstraping

IP Filtering

Cloud Firewall

Secure Bootstraping

oneM2M, Software Defined Device Management

Non IP, Serial or Analog Line

SENSOR GATEWAY SERVICE PLATFORM APPLICATIONSNETWORK

WimFactory Network Security

WIM-XWICON

➊

ID Duplication

Data Leakage

Data Disclosure

➋

ID Spoofing

Data Sniffing

➌

Network Sniffing

Data Tampering

IP Spoofing

➍

Data Tampering

Repudiation

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WinFactory Applications

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BIO - Health and Condition Monitoring

WIM-X

WICON

wicon

CO2 / Humidity

Temperature

Vibration

Other Sensors

CO2 Incubator / Shaker

Refrigerator / Freezer

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Stand-Alone Facility Performance and Condition Monitoring

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WIM-X

ROBOTS - Health and Condition Monitoring

Current

Temperature

Vibration

Other Sensors

WICON

wiconModbusRTU

RS-232/485

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High-Tech Performance and Condition Monitoring

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Compressors - Health and Condition Monitoring

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Turbine Engine Performance and Condition Monitoring

WIM-X

WICON

Modbus/TCP

Ethernet

PCOffice

manager

TabletData

verification of field workers

Smart PhoneRemote real-time monitoring and

notice

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WIM-X

MACHINING CENTER - Process and Condition Monitoring

Process Log

Error Code

Alert

WICON

Modbus/TCP

Ethernet

CTC

T

wiconwicon

WICONCase Study

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Machining Center Performance and Condition Monitoring

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STEELMAKING - Motor Condition Monitoring

UNCOILERROUGHE

LEVELLERSIDE TRIMMER

FINISH

LEVELLERPILERLOOP TABLE F.D.S

WIM-X

WICON

Vibration/Temperature

Electric

Power

Gateway

EPS

WIM-X

Wireless AP

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Technology

wicon wicon wicon wicon wicon

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PRINTING BUFFER REFLOW SOLDERING UNLOADINGLOADING CHIP MOUNTING

WIM-X

WICON

Vibration/TemperatureElectric

Power

Gateway

EPS

WIM-X

wicon

SMT - Machine Condition Monitoring

Wireless AP

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Technology

wicon wicon wicon wicon wicon

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QMS

ERP

SCM

PLM MES

Manufacturing Process Management

WIM-X

WICON

Proximity

Temperature

Thermal

Wireless AP

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wicon

wicon

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Case Study Applications

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Step Case1 Case2 Case3 Case4 Case5 Case6 Case7 Case8 Case9

Plant ClassificationShoes Making

FactoryShoes Making

FactoryInjection Plant

Styrofoam factory

Injection Plant CanCosmetic Class

caseWool, Fabric

PVC film Press out(Extrusion)

Factory location(Country)

China Indonesia Mexico Korea Korea Korea Korea Korea Korea

Products Sports Shoes Sports Shoes Plastic BasketFlame retardant

Shield BoardMotors

Connect PartCan Glass bottle Fabric, Cloth

Greenhouse film

Sensor Type

•Temperature•Voltage•Proximity•Pressure

•Temperature•Voltage

•Temperature•Proximity•Pressure

•Temperature•Voltage•Proximity•Pressure•Laser•RPM

•Temperature•Voltage•Proximity•Humidity

•Proximity•Laser•Voltage•Distance

•Proximity•Acceleromete

r

•Laser•RPM•Distance

•Laser•RPM•Temperature•Proximity

WICON BLE, WIFI BLE, WIFI BLE, WIFI BLE, WIFI BLE, WIFI BLE, WIFI BLE, WIFI BLE, WIFI BLE, WIFI

Apply a system- WIMX- Data Analytics- RT Dashboard

- WIMX- Data Analytics- RT Dashboard

- WIMX- Data Analytics- RT Dashboard

- WIMX- Data Analytics- RT Dashboard

- WIMX- Data Analytics- RT Dashboard

- WIMX- Data Analytics- RT Dashboard

- WIMX- Data Analytics- RT Dashboard

- WIMX- Data Analytics- RT Dashboard

- WIMX- Data Analytics- RT Dashboard

ServerData BankAnalysis serverWeb Server

Data BankAnalysis server

Data BankAnalysis serverWeb / APP

Data BankAnalysis serverWeb Server

Data BankAnalysis serverWeb / APP

Data BankAnalysis serverWeb Server

Data BankAnalysis serverWeb / APP

Data BankAnalysis server

Data BankAnalysis serverWeb / APP

ServiceWeb DashboardPOP System

Data SyncPOP System

Web DashboardMobile APP

Web DashboardPOP SystemMoblie APP

Web DashboardMobile / Tablet APPPOP System

Web DashboardPOP System

DashboardPOP System

POP System

Web DashboardMobile APPPOP System

Other System SPC, ERP QMS - - MES MES GMES MES ERP

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Case 1 : Shoe Making(China, Indonesia)

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Technology

Conveyor – Part Heating Press temperature Heel shape temperature Front shape temperature Shoes shape Press

Chamber No-SEW BPM TA SidePress

TemperatureProximity

TemperatureVoltage

TemperatureHumidity

TemperatureVoltage

PressureVoltage

WIM-X

WICONs

POPDashBoard

Temperature, pressure, proximity, humidity, power

Applied Sensors

• Quality Control by Facilities / Process

• Production and utilization rates

Customer Needs

Operation rate• : 80% ⬆︎ (hourly basis)Defect rate• : 35% ⬇︎MES DATA interworking: Weekly • ➜Daily report

Effects

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Case 2 : Injection Plant (Korea)

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Technology

PCOffice manager

TabletData verification of field workers

Smart PhoneRemote real-time monitoring and notice

Injection facilities

TemperatureProximityPressureHumidity

WIM-X

WICONs

Sensor

Temperature, proximity, pressure, humidity

Applied Sensors

• Quality history data collection

• Two factory data linkage

• MES and POP connection

Customer Needs• Quality factor dictionary detection notification.• Centralized management through HQ• Manual + automatic analysis report / tablet• Faulty product history management ➜ Delivery

management.

Effects

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Case 3 : Compressors Equipment (Korea)

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VibrationMES data linkage

Applied Sensors

Vibration analysis to track the cause of •film production failure

Customer Needs

• Constant frequency oscillation and defect relation extraction ➜ Addition of production volume and electricity data

Effects

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Infographic Case (Korea)

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Number of Machinery

Primarily involved Injetion Mold factory equipment

Wicons per Equipment Total number of Wiconinstalled

Number of Wicon IoT Devices installed per machinery

Wicons = 66

Monthly Unit Price = $10 USD

Malfunction Rate 8%Malfunction Rate 18%

Annual Sales were $2,500,000 USDwith annual loss amount around$450,000 USD with existing loss rate0f 18%

Monthly Loss ~ $33,000 USD

AfterBefore

x3

22

Annual Sales

$450,000Annual Loss Amount

$200,000

Annual Sales

Loss after Improvement

Annual Loss after improvement dropped to $200,000 USD with improvement rate of 10%

Monthly Loss After Improvement = $14,000 USD 50%

Of total Malfunction Reduction in just

3 months

Hyundai Motors Tier-2 Supplier, 2015

South Korea

wicon

Wicon device sales: $27K USD, monthly usage fee: $660 USD ( $8K USD / year)

$2,500,000$2,500,000

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ulalaLAB, Technical and Buniness Partners

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ulalaLAB Partners

ulalaLAB Customers

청년창업투자지주[주]

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If you want to know more about WimFactory,Please feel free to contact us. We always welcome your inquiries!

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Operation HoursAM 10:00 ~ PM 18:00 (GMT+9)

Tel.+82-2-873-0010

E-mailmail@ulalalab.com

ulalaLAB Inc. – www.ulalalab.comNo.614, 6F, 11-41, Simin-daero 327 beon-gil, Dongan-gu, Anyang-si,

Gyeonggi-do, South Korea. (Zip Code:14055)

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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

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