Edge computing architecture supporting IIoT based soluton for advanced smart facotry.

1. • S.K. Cha, Cofounder & CTO
sk_cha@acs.co.kr
IIoT(Industrial Internet of Things)

2. For Smart Factory
DABOM®: To see all in Factory

3. 1. Who is ACS?
Name
Advanced Consulting Services Co.
( http://www.acs.co.kr )
CEO/CTO Sangha Kim/Suk Keun Cha
Solutions DABOM® series
Established August 30, 1988
Capital USD 1.8Million
No of
Employees
72 (as of Jan 2018)
Location GBC, Gasan Digital St. Geumchen Ku, Seoul
Branch
offices
Ulsan, Changwon, Kwangju
Contact Tel: 822-6900-4600, Fax: 82-2-6900-4610
DABOM® means “See all in Factory”‘, ACS Trademark
ACS has been successfully completed more than 1,200 project that started from KIA, Hyundai Motors for ALC
(Assembly Line Control) and POSCO for real time monitoring of production management and slab yard automation
project since its established in 1988 . ACS solution has been certified NeT, NeP, Industrial Excellent Software, Good
Software from Korea Government under multiple patents and local and international R&D project.

4. • Various Device(PLC, Temp, Weight and others)?
• Adding new Device?
• Real time Device data?
• Adding new processes?
• Stable of networks operation?
• Difficult of real time data management !
• System maintenance and upgrade ?
• Existing variety of raw data
• Variety of factory floor data
• Needs various devices connection (WBT, PDA,
display, measurement)
• Variety of real production data type are
available
2. Factory floor for smart factory
Technical problems of factory floor system
Problems of factory floor operation Used past 20
years
No interface

5. Production
Management
& Execution
Planning
Level
Real time 4M1E data inteface
ERP
MES
 Data collection in real time
 Work/data manages in floor
 Alarm/Equipment history
management
 Actuator/sensor interface
Data Level
 Work release for
machine/cell
 Equipment/Tool monitoring
(run rate/status/lifetime)
 Work result report
 Work Order/Recipe
 Job Schedule (machine/cell)
 Process/Shop monitoring
& reporting
Equipment levelShop/floor level
POP
2. Factory floor for smart factory
Real Time 4M1E
MethodMachine Man
Material
To be a Smart factory solution
Real time data management for 4M1E(Man, Machine, Material, Method, Energy)
in factory floor.
Energy

6. 2. Factory floor for smart factory
Transfer to “Smart Factory” that provide predictable quality, maintenance, unexpected production
problems using direct or IIoT based smart device integration to existing device controllers.
IIoT smart devices
• DABOM-GATEWAY
• DABOM-IoT
• TCP/IP
• MIMOSA, OPC-UA,
• MT Connect, SECS/GEM
• Coordinator
• Sensor node
• RS232/422 to TCP
• RS485 to TCP
DABOM®-IOT
Controllers
Wired DABOM®-Device WBT
Mobile
Machine Vision
AR/VR
RFID
DABOM®-Communication Server

7. DABOM
• Challenges for advanced smart factory: Standardization and process/work organization
• need fusion for OT+IT+AT+DT (Autonomous beyond informatization)
2. Factory floor for smart factory

8. 2. Factory floor for smart factory
Platform for rapidly changing production data (4M1E)
• We proposed horizon 4M1E integration in real time by DABOM solutions
RUL: Remaining Useful Life Prediction

9. 2. Factory floor for smart factory
• Complains ISO 20140 Energy evaluation, ISO 22400 KPI for MOM, IEC 62264 Enterprise-control integration
• ISO/IEC JTC 1 IoT reference model for 4M1E integration by automatic, hybrid, manual methods
(ACS has registered multiple Patents & TTA standard for smart factory project in Korea)
Method of Production data 4M1E integration in real time
Sources Data
Machine
Operation time
Run down time
Failure cause
Facility
Voltage,
Current
Flow, Pressure
Watt
Material
Location,
feature,
performance
Product name
Man
Lot no
Start/end time
UPH, Quality
Work activities
Energy
Usages
Time
생산자원 4M1E
Wired Sensor Networks
Device Controllers
RFID
PLC
Machine
DABOM- Device
DABOM-Gateway ERP/SCM/PLM/MES
Enterprise Applications
Protocol Process I/O Sensor I/O
Wireless Sensor Networks
RFID/USN Touch screen Mobile
DABOM-Device
DABOM-Device
Sensors
Sequencer
Access
Point
BCR
Touch
Screen
ISO 20140
ISO 22400
IEC62264
OPC /MIMOSA
ISO JTC 1 IoT
Automatic Hybrid Manual
Big Data, AI
Predictable
Algorithm
Machine
Vision
AR/VR

10. 2. Factory floor for smart factory
• RAMI 4.0, NIST SMRM, ISO 20140 Energy Evaluation , ISO 22400 KPI for MOM
• ISO JTC 1 SC 41 IoT use case ,IEC 62264 Enterprise-Control Integration
(ACS has been participated ISO meeting since 1980 from ANSI-ISA S-95)
ISO/IEC international standard and DABOM®
RAMI 4.0
IEC 62264/ISO22400 ISO20140
ISO JTC 1 SC 41 IoTNIST SMRM

11. 3. DABOM
Characteristics Ordered production Planned production
Product Specification decide by customer Specification decide by
manufacturers
Equipment General purpose Exclusive
Management level ① Delivery
② Quality
③ Cost
④ Usage of production
capacity
① Cost
② Quality
③ Usage of production capacity
④ Customer service
Major issues of
operation
Management of production activity
Management of delivery
Predictable and planned production
Inventory management
ProcessDiscreteProject
Inventorydown
ShortenDelivery
Enhancement of relation
Customer services
Aero space
Ship
Mold
Cement, paper
Chemical, steel
Cost down
CNC
Ind. part
Auto part
EE
Food, Pharm.
Small item, large quantity
Large item, small quantity
Production Quality
Purchase/InventorySales
Quotation to ship
3) Process coverage: sales-purchase, inventory-
production-quality functions
OrderPartPlan
2) Production type & Management point
1) View of production characteristics : Order + Plan production

12. 3. DABOM
• ACS DABOM® Solution designed for 3 IT layers
- ACS DABOM-Application, ACS DABOM-Middleware, ACS DABOM-Device
Multi independence IT
Layers
- DABOM Application
- DABOM Middleware
- DABOM Device
01
Flexibility
02
International
Standard
03
Expandability
04
Convergence
Enterprise Solution
ERP PLM
DABOM Solution
SCM
PDAWBTPLC ETCiDCU RF Tag
Communication Server
Small to Large scale support
Integration
Single sign on

13. 3. DABOM®
ACS DABOM®-Application (Process matrix)

14. 3. DABOM®
ACS DABOM®-Application examples
<Data Grid> <Multi Grid>
<Distribution Chart>
<Chart>

15. 3. DABOM®
ACS DABOM®-Application functionality
Sales
management
Production
management
Quality
control
Outsource
management
Inventory
control
Purchase
control
i18n Service Crystal Report
GUI
Creator
XML
Parser
Excel Report
Dev.Express
Report
HTML
Report
Single
Sign on
Outgoing
control
Mold
control
Standard
information
management
Equipment
control
System
managemen
t
Sales
planning
Outgoing
control
Sales
management
Production
plan
Production
order
Production
execution
Schedule
management
Incoming
inspection
Product
inspection
Outgoing
inspection
Request for
purchase
Order
management
Settlement
management
Outsource
order
Outsource
outgoing
Outsource
incoming
Incoming
control
Outgoing
management
Defect
control
Inventory
movement
Inventory
evaluation
Order
management
Work order
Outsource
process
Production
performance
Non-conformity
process
Use of
raw/subsidiary
materials
Workplace
management
Outgoing
order
Outgoing
processing
Parts
incoming
Maintenance
control
Part control
Inspection
control
Basic code
Product item
information
BOM control
Employee
information
Equipment
inspection
Malfunction
repair
Mold
management
System
code
Other
functions
Maintenance
control
Malfunction
repair
Application Template Manager

16. 3. DABOM®
ACS DABOM®-Application data flow
Sales management Production management Purchase/inventory management
Register of
Quotation
Daily work order
Quality management
Register of order
Approval of order
Register production
result
Material
outgoing
Request material
requirement
Outsourcing
Raw material
incoming
Incoming
inspection
Inter/complete
inspection
Calculation of
production cost
Complete
incoming
Calculation of
inventory level
Shipping
Issue of bill
(Fix revenue)
WIP/Finished
Inventory
Raw material
inventory monthly
closing
Raw material
safety inventory
Stand by auto P/O
Yearly sales plan
Adjust of yearly
production plan
Monthly production
plan
Work center/work
balance
Fixed work order
Incoming of
Outsource
Purchase order
Calculation of material
requirement
Register defect
Register defect
reason
Decision defect
Shipping order
Register of
payment
Register LOT
Issue of product
TAG
Maintenance management
Incoming spare part
Outgoing spare part
Not run/failure
Spare part safety
inventory
Register MRO usage
Collection of quality
data
Set PMRegister
history of
equipment
Material
outgoing
SPC
Issue of
certification
Labor cost entry
(Total employee, working days,
holiday, overtime)
Monthly
closing
Adjust of real
inventory

17. 3. DABOM®
ACS DABOM® application and ISA95(IEC62264)
Order Processing (1.0)
Production Scheduling (2.0)
Production Control (3.0)
Material Energy Control (4.0)
Procurement (5.0)
Quality Assurance (6.0)
Product Inventory Control (7.0)
Product Cost Accounting (8.0)
Product Shipping Admin (9.0)
Maintenance Management (10.0)
Revenue
management Revenue status
Monthly closing Work cost status Work cost analysis
Cost analysis
PM plan History of
equipment
Spare part
safety inventory
Incoming
inspection Not Compliant
Inter/end
inspection
Product
certification SPC
Purchase order
management
Incoming
management
Shopping
management
Raw Material
inventory
Monthly closing
Sales
management
Production
management
Maintenance
Management
Quality
management
Purchase/
Inventory
Management
Equipment
monitoring
Not run/failure
analysis
Sales plan
Cost analysis
Spare part
incoming
Spare part
outgoing
Product data
Raw material
Base
data
Quality criteriaProcess configuration
of itemProcess data
Work center Worker
Equipment data
Work plan
Code management
BOM
Quotation
management Order management
Production plan Production scheduleWork order
Material request Ship management Inventory

18. 3. DABOM®
• ACS DABOM® - more than 80% MES functionality fits manufacturing requirements Solution
functional MESA-11 and ISA-95 standard functions
• ISA 95 (IEC 62264) Enterprise-Control integration and MESA standard complains
ACS DABOM®-Application Evaluation
Source: CGI MES product survey

19. 3. DABOM®
ACS DABOM®-Application Implementation methodology
To-Be
Design
As-Is
Analysis
Large scale MES
skill know-how
ACS DABOM
Middleware
MESA-11/ISA-S95
MES standard
Benchmarking
Fit/Gap
Analysis
Coding
Industry
centric
Bottom-up
Approach
PSDM
< 4 Zero >
Zero waiting, Zero Inv.
Zero Defect, Zero Down
PSDM (Production System Development Methodology)
Industrial software quality (ISO12119)
< Strategy > < Implementation Methodology >
Deliverables

20. 3. DABOM®
ACS DABOM®-Application Global reference
• More than 1,300 ACS DABOM® solution installed in Korea and overseas
• Most of Korean manufacturing enterprises in global distributed multiple factories

21. Sensor/actuator management( DABOM-PM )
Real time data management ( DABOM-RTM )
AndonPrinter DCTRF ID Machines Worker IDCU
(DIO)
PLC
Mold Press Paint Fabrication Assembly Mold
Management
OEE
Management
Real time
Monitoring
Model for production characteristics
Equipment run/down data, productivity, quality, cost and so on.
Device communication interface drivers
COTS (Commercial off the Shelf) based smart solution provides real time data digitalization for
4M1E(Man, Machine, Material, Method, Energy) production resources in factory floor.
3. DABOM®
High reliable data for
ERP/MES/PLM/SCM
ACS DABOM®-Middleware

22. Device Controllers - <Mitsubishi><LS Industry ><Siemens><Fanuc>
Measuring devices <Digital Input/ Output > <Analog Input/ Output >
Sensor/Actuators (Temp , Weight, Pressure), CNC
• Industrial standard driver for various type of device controllers in factory floor
• Various type of drivers for complex device controllers to make simple operation
• Autonomous configuration for flexible operation in adding, modifying and deleting of devices
DABOM-Middleware: Sensor/Actuator management
MIMOSA
OPC-UA
SECS/GEM
Focus
3. DABOM®

23. Real time data management (DABOM-RTM)
DABOM-Middleware
DABOM-PM (CommManager)
PLC OPC IDCU Weighing Temp.
Web Service Method
Database
(SQL / Oracle)
• Manual data in
• Monitoring
WBT
• Shared real time
status
• Data analysis
• History
Data Analysis management
OthersRF Reader
Bar Code
Printer
Sensor/Actuator data management (DABOM-PM (TagServer))
. Status of 4M1E by device
. Generate logging in real time
. Equipment process model
. Task scheduling
. Logging
Device
②
Tag
Address Info.
(Access DB)
①
③
④
⑤
 Data handling procedures
① Define tags (PM)
② Data communication (PM)
③ Data store into shared memory.
④ Data handling (RTM)
⑤ Data store to DB and shared memory.
⑥ Data sharing with other applications
3. DABOM®
Parallel
P1 P2 P3 P4
Shared address space
• Define by parameters and recording to DB for various type of 4M1E production resources
• Provide independent operation between devices and specific processes
• WCF, SOAP, REST
DABOM®-Middleware: Real time data management
Mold Press Paint Assembly
• Big Data, AI
• PUL//GE Predix
• MES/ERP/PLM
• King IOserver
External Appl.
⑥

24. • Solve the bottle neck by XML transaction record from multiple and massive transactions
• Supporting stable operation for massive data of database lock from multilayer data one time operation using
XML Table
Global multiple data Collection Server
3. DABOM®
Factory 1
(Local)
DABOM-Middleware
XMLXMLXML
Database
DABOM-Middleware Manager
DABOM®-Middleware: Expand of Data Management
Factory 2
(Oversea)
Factory 3
(Oversea)
DABOM-Middleware DABOM-Middleware

25. Process matrix based factory floor
management
Communication middleware (DABOM-PM/RTM)
Interface management
 Managing register new device and rule for device entry
 Managing device sensor data collection
 현장 데이터(4M) 변수 등록/삭제/변경
 Monitoring events / Model compile
 설비.작업장 모니터링/ 이벤트관리
 Model management/ model mapping(process
matrix)/back up management
 Authorized/account/property/access management
Model driven management
Operation management
Real time status management
Sensor/Actuator data management (DABOM-PM)
• Solve complex device interface operation by standard
drivers for various equipment device controllers
• Provide easy to use for adding/modifying/deleting of
equipment by standard interface drivers
• Provide property drivers for every PLC type
• Management for Real-time measurement/control
resources, transaction and logging process
• Modifying 4M1E business process parameters/ Event
monitoring for 4M1E business process /data
generation function
• Setting function for remote business process control
Data management (DABOM-RTM)
3. DABOM
DABOM-Middleware: Manager

26.  Device현황/ Tag 현황/ 통신 모니터링
New Device register manager Device data entry rule manager Sensor/Actuator data manager
3. DABOM
• Function for Interface drivers list inquires and register new devices
• Function for communication using equipment interface and communication drivers
• Management for register/modify/delete for physical device information and define of sensor/actuator data
 Register/delete/change for new device
 Update driver list
 Store/read of driver list file
 Manage device entry rule
 Define for register attribute, basic
value, read attribute, entry list etc.
 Sensor/Actuator connection data entry
 ID, IP, Port, Communication cycle
 Read define entry(memory, sensor type)
Interface
definition
Model(Rule)
Management
Setting
management Real time status

27. 4M1E parameter Monitoring event Model compile and apply
3. DABOM
 Register/delete 4M parameter
 Logging 4M1E event parameter process
 Tracking on separate 4M1E parameter
 Register 4M1E parameter audit process
 Generation of within 1 second monitoring
 Register/delete/change for new model
 Run-Time model into DABOM gateway
Interface
Definition
Model(Rule)
management
Setting
management Real time status
• Management register/change/delete of model(rule) of process model for real time data
• Store model(rule) by file for reuse in case of same or similar processes
• Management register for basic value, description, automation of 4M1E ID, monitoring display, data generation
• Management for register equipment operation schedule for change working date, per time, schedule reserve

28. Add/delete of work-center Sensor/Actuator data Select model and sensor mapping
3. DABOM
• Function for remote setting on DABOM-Gateway to definition of operation model(Rule) for work center/device
sensor data/operation
• Function for download for setting data
• Function for definition of auto 4M1E item model setting by process on equipment
 Register/delete/edit for work center
 Definition of work center model
 Work center file read
 Read/store device sensor data
 Define sensor data list
(Device ID, Sensor ID)
 Read/store model data
 Definition work center model
 Definition of sensor and 4M1E data
Interface
Definition
Model(Rule)
management
Setting
management Real time status

29. Real time sensor data Real time status data in work-center Status data history
3. DABOM
• Function for inquire of status of work-center(work order, Product ID, Quantity, run/down etc..) and sensor data in
real time via remote connection to DABOM-Gateway
• Function for simulation for virtual sensor data generation and status of work-center
• Function for operation logging of model(rule) including event type, generation time, data verify
 Register/delete for 4M1E parameter
 Process event logging for 4M1E
 Single event tracking to 4M1E
 Register 4M parameter monitoring
process
 Generation of 1 second monitoring
process
 Register/delete/change for new model
 Run-Time model compile applying to
Gateway
Interface
Definition
Model(Rule)
Management
Setting
Management Real Time Status

30. 2. DABOM-Auto configuration
Auto configuration: Easy to managing 4M1E in factory floor
Traditional procedures (As-Is) Proposed approach (To-Be)
• Auto Configuration provides automatic configurable application program function to 4M 1E(Man, Machine,
Material, Method, Energy) production resources for brings visibility and flexibility
• Almost nothing to do for configuration of 4M1E after once define resources

31. 3. DABOM®
DBMS MS SQL ,Oracle 10g/11g
OS Windows 2012 Ent
Enterprise Library v4.1
WebSerivce
.Net Remoting
TCP / IP
APP DABOM-RTM
Database
APP DABOM-PM(CommManager)
APP
Work Terminal /
Monitoring /
PDA
APP DABOM-PM(TagServer)
PLC
OPC
IDCU
Weighing
Temp Cntl.
RF Reader
BCR
others
Operator
Interface
DABOM-
Middleware APP DABOM-DataLogger
(Optional)
OS Windows 2003/7/2008 R2
FRAMEWORK .NET Framework 4.5
IIS WebService (IIS7.5)
System
DABOM-
Middleware
Manager
Windows 2003/7/2008 R2
.NET Framework 4.5
DABOM-Middleware: iDCU &WBT integration

32. DABOM
(Factory)
DABOM
(WorkCenter) Remarks
Product
Spec. Window2008 R2 Standard (64bit) Windows7 Professional (64bit) OS Spec.
Function Real time process management Real time monitoring for small scale
Terminal
Session
200 ea 20 ea Web service interface
Program
DABOM-PM
DABOM-RTM
DABOM-DataLogger
DABOM-PM
DABOM-RTM
Channel
(Thread)
300 ea 100 ea Work-Center and Equipment
Tag
(Sensor data)
3000ea 1000ea Device real time data
Equipment real time status
Data
Monitoring
0.1 second 1 second Data operation monitoring
DB SQL SERVER 2008 R2 (Optional) SQL SERVER 2008 R2 (Optional) Additional configuration (basic XML)
3. DABOM®
DABOM-Middleware: Specification

33. iDCU-SDA1420R provide stable data transfer using
wireless communication for sensor/actuator interface
in real time
3. DABOM®
Product summary
 Easy to install without cable works
 Provide simple setting when equipment moving
 Protect sensor data into internal flash memory
Product features
 30meters support by 2.4GHz radio Frequency
 Digital Input 4 Port, Analog Input 2 Port
 Serial Input 1 Port, power only needs below 1Watt
Product specification
DABOM-Device: iDCU SDA 1429R

34. 3. DABOM®
iDCU-IoT is embedded Linux based low level of
gateway product provide function for store database
and device management
Product Summary
 Stable system management
 Improvementof managementfor internal Database
 Easy to install supportLAN, WLAN, RF communication
Product features
 LAN support WLAN, 2.4GHz RF support(Optional)
 Digital Input 8 Port , Serial Input 1 Port
 Power only needs 5 watts , Internal DB, 1 month data store
Product specification
DABOM® Device: iDCU-IoT

35. 4. Best Practice for iDCU– P Food Co.
 Focused on right eatable food products
 Annual Revenue : 20 Million USD
 Major Product : Stone Ices, Cup Ices
 Major process: Packaging
Vendor information
 Monitoring of temp and alarm status
 Checking of real product quantity and raw material
 Generation of real time monitoring screen for
accepted & Rejected quantity
Problems
Solutions and User benefits
 Establishing real time visibility
 Accumulating quality data and
hourly temp monitoring data
 Easy to approval to monitoring
system for HACCP certification
Icing
Packing
Reject
store
Hourly temp
check and
manual recording
System Configuration (As-Is)
IDCU-
1420R
IDCU-
Bridge
Hourly temp
check and
manual recording
for reject
Hourly temp
check and
manual recording
for actual production
Hourly temp
check and
manual recording

36. 4. Best Practices for iDCU– Electric part Co.
 Korean best connector vendor for vehicles
 Annual Revenue : 450 Million USD
 Major Products : Connectors, Hannes
 Major Process : Mold, Press, Assembly
Vendor Information
 Cost saving IP solutions for large factory
 No cabling between machines and IT system for
moving
 Real time monitoring for machine run/down
Problems
Solutions and User Benefits
 Right solutions for used IP for large factory
 Real time analysis for run and rejectratio of
every machines
 Good to system maintenancefor large
factory
Use 1 IP
Cable connection
System Configuration(As-Is)
System Configuration(To-Be)
TCP/IP
Use 1 IP
No Cable
Expandable
Good to moving
RF
IDCU-
1420R
Second
IDCU-
1420R
First

37. 4. Best Practices for iDCU – body shop in motor Co.
 First tier vendor of General Motors
 Annual Revenue : 200 Million USD
 Major Products : Frame module, Seat pars, Wheels
 Major Process : Press, Welding, Assembly
Vendor Information
 Production data lost when network down
 Hard to maintain for cabling works
 No monitoring production cycle time
Problems
Solutions and User benefits
 Stable data managementduring network
down
 Solution for neverlost productiondata
 EstablishedEnterpriseAsset Management
system linked production cyclemanagement
System Configuration(As-Is)
System Configuration(To-Be)
TCP/IP
Automatic data transfer
due to internal DB when
Reconnection networks
DB
RF
IDCU-
1420R
IDCU-
IoT

38. 4. Best Practices for iDCU– Die casting manufacturing Co.
 Die casting expert for electronics and motors (Mg,
Al)
 Annual Revenue : 20 million USD
 Major Products : Steering parts, Electronics parts
 Major Process : Mold die casting
Vendor Information
 No real time OEE monitoring
 No real time quality control system
 Increasing cable works
Problems
Solutions and User benefits
 Establishedreal time SPC system by direct
interfaceto machines
 Good to OEE operation
 Easy to moving of machineswithoutcable
works
System Configuration(As-Is)
System Configuration(To-Be)
TCP/IP
RF
Real time monitoring for
Quantity, Run/Down data
TCP/IP
AP
Wi-Fi
Real time SPC system by
direct interface to machines
IDCU-
STE
IDCU-
IoT

39. 3. DABOM®
• Thin client touch screen WBT (Windows Based Terminal)
- IT resource in servers, no IT resource in terminal as just plug & play
- Low power consumption, good for harsh environment
- No issue of hacking and IT security
- Easy to manual data entry by workers – display big characters & touch
• Managing by moving for multiple equipment
- Work order & report by mobile for production and
maintenance
- PDA and smart phone integration
• VR/AR integration
DABOM®-Device: WBT integration examples

40. 3. DABOM®
iTouch provides no hard disk and pan that brings
benefits of reduced maintenance cost in harsh
environment
Product
 Provides high security and safety
 Reducedmaintenancecost
 Touch function supportingwithoutkeyboard, mouse
Product feature
 LAN, WLAN support
 Serial Input 1 Port
Product Spec.
7 Inch 10 Inch
12 Inch 15 Inch
DABOM-Device: WBT

41. 3. DABOM®
DABOM-Device: WBT example

42. 예지정비의 적용 예Predictable Maintenance
Absolute decision,
Relative decision,
Reciprocal decision
Device item no.
Decision level
DABOM Gateway
Record for time series trend factors
Verify abnormal symptom pattern
Pre abnormal symptom pattern
level setting
Input setting condition of warning
generation level
Pattern
level
modify
Y
N
Time series data analysis server
(Big data + Machine Learning, AI)
Action
convey PumpCNCRobot
Fault Diagnosis ModelCorrelation Analysis Multivariate Analysis
4. Best Practices for advanced Smart Factory

43. Predictable Quality
DABOM Gateway
SPC data and time series multivariate
Analysis
SPC data abnormal symptom pattern
analysis
Pre abnormal symptom pattern level
setting
Level
Decision
Y
N
SPC Server Quality Data Analysis Server
Action
Quality data
Quality data
Absolute decision,
Relative decision,
Reciprocal decision
4. Best Practices for Advanced Smart Factory

44. 4. Best Practices for Advanced Smart Factory
QCD vs. Energy & Climate change
Analysis for Process and cycle time with energy usage
Integration
Utility Process HVAC
Horizon Integration between
MES and FEMS
Vertical Integration between
ERP/PLM/SCM and MES
Register
Integration

45. CPPS (Cyber Physical Production System) Digital twin
Graphic Lib. After 3D modeling for equipment
Build virtual Reality based on Library
Digital Twin
VR
Training
CPPS
PLC
Verify
Process
Standard
4. Best Practices for Advanced Smart Factory

46. Rent for Manufacturing support IT (POP/MES)
Sales
Production
Financial
Quality
Mfg. cost
Procure/Inv.
Production
Process Maintence
Quality
Product plan
verity
Layout
review
3D Virtual Factory
Network
VPN
TechnoParkIDC
현장단말기
Factory 2 ~ Factory 10
Work order
WBT
Factory 1
•Production Order
•Product inventory
•Base data
•Product actual
•Defect data
•Product actual
•Defect data etc
•Product actual
•Not Run reason data
•Defect data
4. Best Practices for Advanced Smart Factory
BCR Board PDA PLC
Board PDA PLC

47. 4. Best Practices for Advanced Smart Factory
Benefits of rent for Manufacturing support IT (POP/MES)
Index Detailed index
Y Co.
(Before)
After Goal
Work order Time for work order release 1 Hour 15 Min. 3 Min.
Time for survey of daily
inventory level
Time for survey of daily inventory 5 Hours Real time Real time
Time for reporting 5 Hours 10 Min. 5 Min.
Time for daily work report
Time for work report 3 Hours 15 Min. 5 Min.
Time after collection of work report 2 Hours 15 Min 5 Min.
Total 16 Hours 55 Min. 18 Min.
Index Detailed index
K Co.
(Before)
After Goal
Time for survey of daily
inventory level (Raw materials,
Product goods, WIP
Time for survey 3 Hours Real time Real time
Time for daily sales report
Time for sales report Real time Real time Real time
Time after collection of sales
report
1 Hour Real time Real time
Time for reprot
Time for closing logistics 15 hours 10 Min. 5 Min.
Time for financial report (5 Hours) - Real time
Time for monthly report 10 Days 5 Days 3 Days
Total
10 Days 19
Hours
5 Days 10
Min.
3 Days 5
Min.

48. 4. Best Practices for Advanced Smart Factory
Quality analysis for casting condition in real time



TCP/IP
RS232/Ethernet
DABOM-Gateway Monitoring ERP/MES@ CTP
Supporting
for
disconnection

49. 4. Best Practices for Advanced Smart Factory
Quality analysis in real time application
Advanced MES functions
Ref. Data
Process
Plan
Production
Mgt.
Quality
Mgt.
Maintenan
ce Mgt/
Mold Mgt. Inventory Notices
Common
code Mgt.
Production
Mgt.
Production
Status
Casting
condition
Mgt.
ERP Interface
Touch screen
Work
order list
Work
status
Defect list
Not run
list
Actual list Inspection melting Scrap
Condition
verify
Work history Defect type
주조조건항목등록
Casting
Condition
Ref Data
Casting condition
information by equipment
Casting conditions by item
Casting monitoring settings
History by casting
condition
History of Casting
Condition by Serial No.
Condition value vs.
measured value
Setting value vs.
measured value
X-Bar R Chart
Normal distribution table,
CpKSet up data collection by
facility Output condition history
by serial numberDesign condition
management for each
mold by equipment
Printing
Printing
New Add
functions
New add screen

50. 4. Best Practices for Advanced Smart Factory
Textile industry (World No. 1 dying Factory)
Web
Client
PC
Dying
Machine
TCP/IP
Hybrid
Connection
Tender process
DABOM-Gateway
(#MAIN Factory)
DABOM-Gateway
(MAIN/Factory #2)
DABOM-Gateway
(Factory #1)
Real time
Agent
Automation
Connection
Manual Data
collection
(20ea)
Tender process
Automation
Connection
Tender process
Automation
Connection
Tender process
Automation
Connection
GD MES / Real time monitoring
MES
Manual Data
collection
(7ea)
Manual Data
collection
(26ea)
Manual Data
collection
(7ea)
Hybrid
Connection
Hybrid
Connection
Hybrid
Connection
Dying
Machine
Real time
Agent

51. 4. Best Practices for advanced Smart Factory
Monitoring of dying processes
Word order No./Worker/Not run code/Fault code/Repair status/complete
Run/not Run/Equipment status data
Purpose
 For global competition, must provide operation status of every equipment, production status, logistics,
key performance indication for every production processes in real time
System
Interface
Data
&
Screen
shot
 Real time monitoring
 [Run/Not Run]
 Run> Real time equipment status
 Run> Daily performance index status
 Run> Run status by period
 Run>Trend analysis run rates
 Not Run status>Not run history
 Not Run status>Not run history by period
 Not Run status>TOP 5 analysis
 [Fault]
 Equipment mgt. status > MTTR/MTBF
 Equipment mgt. status>Equip. fault history
 Equipment mgt. status>Fault status by
period
 Equipment mgt. status>TOP 10 analysis
 Equipment mgt. status>Equipment Fault
analysis
DABOM-Middleware WBT
DABOM-Device (IoT)

52. 4. Best Practices for Advanced Smart Factory
Single instance MES for multiple factories
Total WBT No: 454 ea
Total No of equipment
connection: 2,105 ea
Plant #1
Plant #2, #3
Plant #5
Plant #4

53. 4. Best Practices for Advanced Smart Factory
Screen shot of multiple factories

54. 4. Best Practices for Advanced Smart Factory
Sensor based mobile app. Platform for manufacturing innovation (R&D Project)
MES Application
(IEC 62264 S-95)
4M1E Interface module (H/W)
CoAP/DTLS/128bit AES
ISO JTC 1(SN, IoT)
Industry centric production processes
Manufacturing
Innovation
service Contents
(Q,C,D,F)
ERP, G/W
G/W
SNS
통신 모듈
4M1E DB
Industry Cyber
Security
UC
PI DI AI
Industry Template
Developer
4M1E Tag
Setting
Parameters
4M1E
Auto-
configuration
4M1E digitalization module (S/W) ISO22400(KPI),
ISO20140(Energy)
UI/UX Component
Industry
App.
setting
KPI Loop
App Generation Tool
4M1E: Man, Machine, Material,
Method, Energy
PI: Process Integration
DI: Digital Integration
AI; Analog Integration
UC: Unified Communication
Mobile Device
Real time Loop
CoAP: Constrained
Application Protocol
DTLS: Datagram
Transport Layer
Security
AES: Advanced
Encryption Standard
App. Platform
SNS API
module
Sensor add
module
Auto-
configuration
UI/UX
C
L
O
U
D
G
A
T
E
W
A
Y
S
E
N
S
E
R
S
Layers
Sensor node
Rich
Web
Hybrid
Web
Widget
Real time
middleware

55. 4. Best Practices for Advanced Smart Factory
Real time feedback and KPI feedback
Web Services/Database Server
4M1E Integration
(DABOM Gateway)
Heat treatment
Casting
Metal fabrication
Realtime Search
/ Manual Operation
Mobile Server
IoT Devices
Monitoring
•
•
•
•
•
•
•
•
•
•
•
•
• Finished goods ratio
•
•
•
KPI Feedback
Auto-Configuration

56. 4. Best Practices for Advanced Smart Factory
Example

-
-
-

-
-

57. 5. User benefits
for production

58. 5. User benefits
Technical view
Total Cost Ownership view

59. 5. User benefits
ACS future collaboration business model

60. 6. Why ACS!
Patents & Certificates
Multiple patents registered
 Industrial software quality (ISO12119)
 Good Software certified
 NeT, NeP certified
 ISO/IEC standard functional support
1,300+ references
Most of ERP/PLM/SCM interface skills
 Small to Large scale MES skills
 Standard methodology support
Excellent maintenance
 7 x 24 operation support for both
oversea and local
Remote maintenance support skills
 local self maintenance support
Optimal for Mfg.
 More than 80% function for
manufacturing requirement
 Good to rapidly change production
processes
Industry centric
Automotive part Mfg.: most of 1st
venders
Electric/Electronics Mfg.: Simtech, Baun
Electronics etc.
Industry part Mfg.: Shinil, Sanah Numetic
New ICT on
Web Mobile supporting
Real-time Interface and Data
management
 Big data. AI/ML/DL, IIoT supporting
ACS
DABOM®
ACS vision: pride, Attainment, share!