“Towards the CYBER FACTORY”

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

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

3. Manufacturing Paradigm Shifts versalog mass-customized, low-volume, high-mix Sum of All Manufacturing types Mass Customisation mass-produced, high-volume, low-mix Mass Production Options ++ Mass Production Craft 1900 1910 1980s 2000 Different philosophies for manufacturing are needed

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. - The Evolution of Control Technology- versalog Functionality Increases 109 HOLONIC 108 107 106 Granular H/W 105 Distributed 104 103 Hierarchical PLC Structure 102 PLC 101 Relay Solid State Control 100 1930 1940 1950 1960 1970 1980 1990 2000

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

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

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

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

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

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

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

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

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

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

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

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

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

20. Holonics- 101 – in business versalog • Holonics is happening in business practice, even though they don’t know it. • 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.

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

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

23. Agents in Manufacturing versalog 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. Agents in Manufacturing • So what to do first? First a little structure is needed versalog IncreasingCost of Change MRP MES IncreasingDemand for Change Cell Multi Site Machine

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

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

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

28. The Human Factor versalog 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. What ColinWants versalog Reasoning Systems CH Biological/”Life forms” Holonic Controls Autonomy Co-operation Intelligence Learning Systems Rule Based Software Programmable Devices Command Based Software Dumb Hardware Relay/I/O points

30. The Cyber Factory versalog 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 there’s still a long way to go.

31. The Cyber Factory versalog That’s All, Folk. Thanks……..