Dennis Brandl

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the big picture integrated manufacturing systems

• Dennis Brandl
• BRL Consulting

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Integrated Manufacturing Systems

• Because manufacturing is not getting slower
• Because manufacturing is not getting easier
• Because the world is not getting safer
• Because manufacturing productivity increasing
  3/year
• Because its not your fathers manufacturing
  environment

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Integrated Manufacturing Systems

• Because 6 sigma is just not good enough!
• And manual integration is a 3 sigma process
• Because Moores Law is driving everyone!
• Because Metcalfes Law applies to manufacturing!
• Because we have to!
• Because we can!

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The Value of Integrated Systems

• Metcalfes Law
• The value of a network is proportional to the
  square of the number of users of the system (n2)
• The more connected, the more the value
• Real networks are scale-free
• In integrated systems you are always just 1 to 3
  steps away from any data

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The Value of Accessible Data

• Manufacturing Workers becoming Knowledge Workers
• 80 of time seems to be spent finding information
  and only 20 of the time using it
• Real benefits
• Leaner manufacturing supply chains, fewer errors
  than manual information exchange, better control,
  faster startups,

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Integrating What ?
Level 4
4 - Establishing the basic plant schedule -
production, material use, delivery, and shipping.
Determining inventory levels. Time
Frame Months, weeks, days, shifts
Business Planning Logistics Plant Production
Scheduling, Operational Management, etc
Level 3
Manufacturing Operations Management Dispatching
Production, Detailed Production Scheduling,
Reliability Assurance, ...
3 - Work flow / recipe control to produce the
desired end products. Maintaining records and
optimizing the production process. Time
Frame Shifts, hours, minutes, seconds
Level 2
Manufacturing Control Basic Control, Supervisory
Control, Process Sensing, Process Manipulation,
2 - Monitoring, supervisory control and
automated control of the production process
Level 1
1 - Sensing the production process, manipulating
the production process
Level 0
0 - The physical production process
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Integrating Applications
Business Logistics Systems (ERP)
Level 4
4 - Establishing the basic plant schedule -
production, material use, delivery, and shipping.
Determining inventory levels. Time
Frame Months, weeks, days, shifts
Business Planning Logistics Plant Production
Scheduling, Operational Management, etc
Manufacturing Operations Systems (MES, Batch,
LIMS, AM, )
Level 3
Manufacturing Operations Management Dispatching
Production, Detailed Production Scheduling,
Reliability Assurance, ...
3 - Work flow / recipe control to produce the
desired end products. Maintaining records and
optimizing the production process. Time
Frame Shifts, hours, minutes, seconds
Control Systems (PLC, DCS, OCS, )
Level 2
Manufacturing Control Basic Control, Supervisory
Control, Process Sensing, Process Manipulation,
2 - Monitoring, supervisory control and
automated control of the production process
Intelligent devices (Vision, Flow,
Level 1
1 - Sensing the production process, manipulating
the production process
Level 0
0 - The physical production process
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Architecture Of Integrated Manufacturing Systems

• Moving to smaller devices with embedded control
  and networks
• Moving to a hierarchy of control implemented in
  hardware appliances
• Combined Hardware Software
• Limited Functionality
• Easier replacement
• Easier configuration
• Standard interfaces are available at the network
  level
• Ethernet TCP/IP, XML, OPC-UA, SOAP,
• No suitable interfaces available at the software
  level

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Networks inIntegrated Manufacturing Systems
Level 4
ERP, APO, Logistics Systems
Business Information Networks
Level 3
MES, LIMS, WMS, CMM Systems
Operations Information Networks
Level 2
HMI, SCADA, Batch Systems
Automation Networks
PLC, DCS, Packaged Systems
Device Networks
Level 1
I/O, Devices, Sensors
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Safety inIntegrated Manufacturing Systems
Redundant connection to corporate distribution
switches
Firewall
Router Switch
Printer
MES/SCADA Client
SCADA Server, Historian Server, Database Server,
Print Server,
Firewall
Router Switch
Device Networks
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Important Elements for an Integrated
Manufacturing Environment

• Integration of Level 3 Level 2 systems
• Addressed by Make2Pack ISA 88 Part 5
• Packaging Systems
• Significantly reducing information integration
  time
• Machine Tools
• Significantly reducing implementation time
• MES
• Managing across production lines
• Integration between ERP and shop floor
• Secure and Supportable PCs Networks
• Safety and security in an integrated environment

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the big picture integrated manufacturing systems

• THEY ARE COMING
• BE PREPARED
• Dennis Brandl
• BRL Consulting