Showing posts with label Cisco Manufacturing. Show all posts
Showing posts with label Cisco Manufacturing. Show all posts

Sunday, 1 December 2019

Automated Networks for Flexible Manufacturing Cell’s

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Competing in the industry as a manufacturer isn’t just about controlling costs. It’s about building an agile company that can deliver exactly what the market demands—today and tomorrow. Yet as product lifecycles get shorter every day, it doesn’t make things any easier in a mass production environment. So meeting customer needs today now requires you to not only keep operations efficient but also flexible—So you can respond quickly to each specific customer order and scale to the ever-demanding needs of the operations and manufacturing teams. 

Manufactures have been faced with a dilemma. A dilemma they only deal with when orders are not shipping.  For instance there is the minimum equipment needed to make the product which has a known but more often an unknown maximum yield. The schedule is based on the time it takes to make product which is equal to or less than the maximum yield of the machine.  When the yield falls below the schedule the unit profit is then lost and may be unrecoverable.  What makes this more difficult is that production lines are built for long runs of a given product.  These productions lines are not easily changed to build a different product.

This inability to change easily creates a financial boundary for many manufactures.  They won’t even attempt low volume production thus keeping some products off the market entirely or the manufacturing is moved offshore to a location with a low labor rate for manual manufacture. 

Manufactures have long wanted to be able to accurately measure yield.  Improve yield and you improve profits.  This assumes the schedule to meet orders approaches 100%.  If the orders for a given product falls can the line be easily reconfigured for another product?

One of the systems that may also need to be reconfigured is the network.  Cisco has been working to make network changes easy, even automated.  Therfore it was fortunate to come across the folks at the Commonwealth Center for Advanced Manufacturing (C-CAM) near Richmond Virginia.  They have just received a grant from the National Institute of Standards and Technology (NIST) to research the viability of the flexible manufacturing cell.  The purpose is to develop a profitable easily reconfigurable production cell for short and varied production runs.

To get the data from the production equipment will require a well–connected network.  So that well–connected network can and should include data collection via embedded edge computing.  Security for in plant and remote access to the data.   We believe that C-CAM is onto something that can revolutionize manufacturing in the U.S. and Cisco is proud to be participating with NIST and C-CAM in this endeavor. 

Wednesday, 19 June 2019

Relying on secure wireless in harsh environments

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We announced our next generation heavy duty industrial wireless platform, the IW6300. This Class 1, Div 2, IP67 rated intrinsically safe WiFi mesh access point capable of handling some of the most challenging working environments. These harsh operating environments are often found in open mine pits, refineries, paper & pulp manufacturing plants, oil platforms, factory floors, and chemical plants.

What’s new


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Those familiar with Cisco’s industrial products will be quick to point out that the IW6300 isn’t our first wireless product to work in these harsh environments. In fact, our current HazLoc certified WiFi access points, the Cisco Aironet 1552 series, have been going strong for over eight years, including models that offer embedded industrial wireless protocol support from our industrial partners Emerson and Honeywell. The IW6300 builds upon the Cisco 1552 series capability of delivering rock-solid, secure WiFi connectivity to the harshest working environments by adding updated WiFi standards with improved throughput (802.11ac Wave 2), improved security (WPA3), better RF interference avoidance (Cisco CleanAir), reduced size & weight, improved temperature range, additional PoE options, future Cisco IOx edge compute support, and modular IoT expansion capability. This modular expansion capability is significant because it allows companies the flexibility of deploying WiFi coverage for connected worker solutions and later expand the solution to handle future IIoT connectivity modules, including the popular industrial wireless standards of ISA100 and WirelessHART, to support connected factory and connected plant solutions.

Connecting the unconnected


Reliable and secure WiFi has become the new normal in the carpeted office spaces, allowing office workers access to the corporate network and SaaS applications anywhere they go in the corporate offices, however, the non-carpeted spaces of factories, plants, mines and production facilities have remained widely unconnected, limiting the productivity improvements that connected workers are capable of delivering. The Cisco IW6300 heavy duty series access point will allow companies to deploy pervasive high-speed secure WiFi mesh connectivity to the non-carpeted spaces for both IT and OT connected worker applications with the flexibility to add industrial wireless support through an optional IoT add-on module. The ability for this platform leverage WiFi mesh, connecting remote mesh access points to the network without wires through the root access points, lowers the cost while improving the deployment time in areas with harsh environmental conditionals.

Simplify with new capabilities


While many industrial wireless protocols are capable of forming their own industrial wireless mesh, the ability to leverage a WiFi mesh network to backhaul sensor traffic just makes everything easier. By adding an Industrial IoT module to the IW6300, the industrial protocols see fewer “hops” in the industrial wireless network, have higher backhaul throughput, and all of the benefits of having the 802.15.4 IoT wireless gateways directly connected to the Ethernet network, without the cost of physically connecting them to the wired network. Another major advantage of leveraging the Cisco IW6300 to backhaul field device sensor traffic via the IoT expansion module is our ability to separate the IT traffic from the OT traffic. Many industrial and manufacturing companies follow industrial automation and control systems best practices for security, like those found in ISA99 and IEC62443, that segment ICS traffic from IT and end-user traffic. With an add on IoT module for the IW6300, we’re able to support these standards and keep WiFi user traffic segmented from IoT wireless sensor traffic.

Digital transformation is a journey and the Cisco IW6300 is the next generation industrial wireless platform to enable wireless connectivity in some of the most difficult to reach areas. I’m excited to see what kind of worker productivity, operational efficiency and improved safety outcomes our partners like Honeywell will be able to help our joint customers achieve through this next generation industrial wireless solution.

Wednesday, 24 April 2019

Connected Car – What is Your Vehicle Reporting?

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We looked at In-Vehicle Infotainment, focusing on streamed media and navigation services. In this blog, we’ll look at Connected vehicle services and telemetry. What is this and what data volume does it represent?

Vehicle services


Some vehicle manufacturers such as Jaguar, provide additional information services to the vehicle owner/user. For example, the InControl service includes the ability to report completed journeys. This function provides the customer with information about their journeys including the journey distance, real-time location, the duration of the journey, the average speed and data about the efficiency of the journey.

The information required to offer this function is derived from existing vehicle telemetry that is collected by the vehicle manufacturer. Such information forms a small part of the overall vehicle telemetry that is sent over a cellular connection to the vehicle manufacturer.

A growing number of manufacturers offer ‘remote-control functions’ using a cellular connection, enabling users to perform such functions as enable the heating/air-conditioning, lock or unlock the vehicle, sound the horn, flash the headlamps, check the fuel level or battery charge and effective range, check current location etc. More advanced functions include ‘summoning’ the vehicle, however, these services require a relatively small data exchange between the vehicle and the vehicle manufacturer’s data-center.

Some vehicle manufacturers such as Tesla are using software and firmware update over-the-air. In some cases, these updates are delivered via a cellular connection. In others, WiFi can be used as an alternative delivery method. Anecdotal reports from various driver forums suggest that for Tesla vehicles, the full version updates take place roughly every 6 months, with the version 9.0 update required a download of approximately 1GB. Periodic firmware updates also occur but these are unannounced and are much smaller in size (100-150MB). Over-the-air updates are of significant value to vehicle manufacturers in addressing potential defects or in delivering new capabilities to a vehicle, post-sale. Discussions with a small sample of vehicle manufacturers have identified that some are currently reluctant to use over-the-air updates for anything other than updates to non-safety related software such as infotainment services due to concerns about managing the associated risk.

What is your vehicle reporting?


Vehicle manufacturers are increasingly building their vehicles to be ‘connected’. While some manufacturers gather such information for a limited period of time (typically covering the warranty period) others gather information throughout the lifetime of the vehicle.

BMW collects information including vehicle status information (e.g. mileage, battery voltage, door and hatch status, etc.), position and movement data (e.g. time, position, speed, etc.), vehicle service data (e.g. due date of next service visit, oil level, brake wear, etc.), dynamic traffic information (e.g. traffic jams, obstacles, signs, parking spaces, etc.), environmental information (e.g. temperature, rain, etc.), user profile (personal profile picture/ avatar, settings as navigation, media, communication, driver’s position, climate/light, driver assistance, etc.) and sensor information (e.g. radar, ultrasonic devices, gestures, voice, etc.).

In cases such as a detected fault condition, the information including Diagnostic Trouble Codes (DTC) will be recorded to local storage within the vehicle. This can subsequently be used by service engineers to determine the fault condition that was encountered. Some vehicles will send a summary fault report to the vehicle manufacturer, as well. As more sensors are added to vehicles, not only will vehicle manufacturers gather information about the performance and operation of the vehicle itself but may also gather data generated from the sensors themselves­2. This does not mean that such data is gathered continuously. Vehicle systems may transmit a form of the sensor data in cases of ‘interest’ such as an accident or an unexpected set of telemetry data being recorded. Such information is of interest to not only the vehicle makers but potentially to organisations such as insurance companies.

As one can see from the information collection details, the manufacturers are collecting far more information than just fault conditions. The position and movement information can include details such as braking and acceleration styles. Traction-control indications can help determine road conditions at a location. Some vehicle makers and mapping service providers are starting to use such information to identify roadway hazards such as potholes.

Such services are designed of course, on the premise of having cellular connectivity coverage. However, very few countries are able to provide ubiquitous coverages. A 2017 report noted that the United Kingdom had 91% coverage of national highways but a much lower 58% coverage of non-highway classed roadways. A 2017 report indicates that most major urban areas in the United States have good cellular coverage but with the large geography covered by the US highway system, there are still many locations where cellular services are patchy at best.

From a vehicle manufacturer’s perspective, one cannot rely on universal cellular coverage. As a result, applications need to be designed to operate on the premise that connectivity may or may not be available and therefore vehicle systems need to include the ability to store critical data locally, transmitting valuable information when connectivity is restored.

Data volume today

How much information is the vehicle transmitting to the vehicle manufacturer and when is it taking place? The data volume varies from manufacturer to manufacturer and will also depend on the type and model of the vehicle.

A study performed by ADAC in 2016 identified that the BMW i3 electric vehicle transmits the ‘Last State Call’ automatically every time the driver switches off the car and locks the doors (vehicle is not in motion). This call includes the content of the error memory, battery details including cell temperatures and charge level, the driving mode (eco, eco plus, sport), operational data of the range extender, the mileage at various driving operations, quality of the charging point including malfunctions and the position of the last 16 charging points used.

Key to note that in the BMW case is that some information is obtained while the vehicle is in motion, with other information being collected at the end of the journey. Information provided by OEM A (a Japanese auto-maker) indicates that their personal light vehicles generate a report of ~10-15MB per duty-cycle. This is collected on a monthly basis in an upload over a cellular LTE connection. Information from OEM B (a Japanese auto-maker) indicates a volume of 15-20MB per duty-cycle collected while the vehicle is in operation where the average ‘driven-day’ in Japan is ~90 minutes, equating to a US duty-cycle volume of ~12MB.

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How does this compare to the typical smartphone users? According to a 2018 report, monthly mobile data traffic per smartphone in North America reached 8.6GB (286MB per day) by the end of 2018.

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Thursday, 29 March 2018

Cisco and Sentryo work together to help secure factory networks

Manufacturers, utilities, and oil & gas companies are using data and applications to improve business operations through smart manufacturing initiatives like Industrie 4.0.  To accomplish these benefits these companies recognize the need to converge their enterprise network and their factory networks with industrial Ethernet to gain a 360-degree view of their operations across a single network infrastructure. They also gain real-time network diagnostics and troubleshooting.

Monday, 19 February 2018

Manufacturing mobility: Data, voice, video, and location

Manufacturers use wireless to increase margins, reduce cycle times, enable lean, and improve equipment productivity. While pervasive wireless connects sensors, tools, robots, AGVs, and RFID devices, it also enables mobility. Mobility supports far more than just cell phones, tablets, and laptops.

Very simply put, mobility drives data, voice, video and location applications.

Monday, 1 May 2017

Lessons from Hannover Messe: 5 Ways to Leverage IT for Your Industrial Ops

Our customers are already connecting thousands of intelligent devices and demanding new transparency from their vendors: They want to liberate plant floor data from operational silos and proprietary technologies. Only by doing this will they be able to adapt to the latest advances in automation, sensor technology, and machine learning… not to mention the economic imperative to get in front of tightening competition due to globalization.

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