Information, People, and Technology

Manufacturing

Based on TCS 2013 Global Trend Study, improvements in supply planning and product quality provide the greatest benefit of big data for manufacturing. Big data provides an infrastructure for transparency in manufacturing industry, which is the ability to unravel uncertainties such as inconsistent component performance and availability. Predictive manufacturing as an applicable approach toward near-zero downtime and transparency requires vast amount of data and advanced prediction tools for a systematic process of data into useful information. A conceptual framework of predictive manufacturing begins with data acquisition where different type of sensory data is available to acquire such as acoustics, vibration, pressure, current, voltage and controller data. Vast amount of sensory data in addition to historical data construct the big data in manufacturing. The generated big data acts as the input into predictive tools and preventive strategies such as Prognostics and Health Management (PHM).

Cyber-physical models

Current PHM implementations mostly use data during the actual usage while analytical algorithms can perform more accurately when more information throughout the machine's lifecycle, such as system configuration, physical knowledge and working principles, are included. There is a need to systematically integrate, manage and analyze machinery or process data during different stages of machine life cycle to handle data/information more efficiently and further achieve better transparency of machine health condition for manufacturing industry.

With such motivation a cyber-physical (coupled) model scheme has been developed. The coupled model is a digital twin of the real machine that operates in the cloud platform and simulates the health condition with an integrated knowledge from both data driven analytical algorithms as well as other available physical knowledge. It can also be described as a 5S systematic approach consisting of sensing, storage, synchronization, synthesis and service. The coupled model first constructs a digital image from the early design stage. System information and physical knowledge are logged during product design, based on which a simulation model is built as a reference for future analysis. Initial parameters may be statistically generalized and they can be tuned using data from testing or the manufacturing process using parameter estimation. After that step, the simulation model can be considered a mirrored image of the real machine – able to continuously record and track machine condition during the later utilization stage. Finally, with the increased connectivity offered by cloud computing technology, the coupled model also provides better accessibility of machine condition for factory managers in cases where physical access to actual equipment or machine data is limited.