Toward Realization of
Smart Manufacturing Systems
Case: A cyber-physical manufacturing system enhancedwith collective knowledge
March 2017
Robot Revolution Initiative
WG for Manufacturing Business Revolution Through IoT
The Industrial Machinery Steering Committee

Supported by:Cyber-physical manufacturing system enhanced withcollective knowledge
 Cyber-physical manufacturing system: Collection of ideally every piece of
information available in a manufacturing system and global optimization of the systemthrough the analysis of the collected information in the Cyber space.
 Kaizen style: Line operators and administrators in a shop floor provide onsite andastute judgments about improving productivity based on their own knowledge andexperience (by means of accumulation of local optima).
 A mechanism to reflect collective knowledge about the judgments in the Physical space
to the Cyber space is a key to the integration of the above two concepts, which realizes
circulation of Kaizen that links both spaces for a truly smart manufacturing system.
D‐Maintenance

Circulation of Kaizen

D‐Quality Control

Maintenance

D‐Prod. Control

Prod. Control

D‐OperatorOperator

D‐WorkD‐Machine tool

Quality Control

D‐Sensor

Digital (Cyber) World (Space)

Reflection ofcollective knowledge(ex. judgment of line workers)

Machine toolWorkSensor

Real (Physical) World (Space)1

Proposals
 The concept of a cyber-physical manufacturing system enhanced by collectiveknowledge such as on-site human judgments as the core of Kaizen.
 An information modeling for the investigation of machine tool interface* (regarding thetype of information) that transfer on-site human judgments to the Cyber space.
*In the report, machine tool interface refers to interface for the mart
manufacturing, in which machine tools are served as its core.

Members

Steering committee (ʻ15-)
Mainly board members

The concept of smart factory andmachine tool interface skeleton (ʻ15)
Cyber-physical manufacturing systemenhanced with collaborative knowledge (ʻ16)
Strategy for standardization (ʻ16)

Interface working group (WG)
Mainly senior engineers (ʻ16-)

Information modeling for CPS (ʻ16)
Machine tool interface investigation with use cases (ʻ16)
Cyberspace

Physicalspace2

Information modeling

Cyber Space

Physical Space

The Cyber space is a mirror of the Physical space.
Modeling actions (e.g., machining), directions (e.g.,machining order), judgments (e.g., quality control), andother information flows occurred to among thecomponents (e.g., machine tools, operators, data).

Information modeling
Cyber Space

Physical Space

Components in the Cyber space specify their attributes but
not their functions (i.e., “What a machine tool ought tobe” but not “What a machine tool should do”)
Visualization of feed-back loops at various levels
indicating local and global evolution of cyber-physicalmanufacturing systems.
Output: Machine tool interface is clarified by unificationof information models with respect to each use case(next three slides).
••••••Physical states (ex. speed)
Operating status (ex. running)
Machining information (ex. NC program names)
Actual state in comparison with planned state
Degeneracy movement directions
Alarms and warnings

ActionComponent
Information
Direction

Judgment3

Case 1: Operating status tracking and management
 Present: Experienced workers plan and review at weekly or monthly basis, but plans
should be reviewed as required if it is urgent.
 Future: Realization of more frequent and detailed review of production/maintenanceplans, while facilitating use of idle machine tools for improving productivity.
Cyber SpacePhysical Space

Complex information flow is inevitable for collecting
operating status without increasing operatorʼs burden.

Integration of information obtained from machine tools aswell as other machines (ex. material handling machines)
Bidirectional information flows at the interface between
the shop floor and the production control is clarified.

Model changer will support the evolution of theproduction plan in the Cyber space considering
unexpected incidents in the planning phase.

4Case 2: Quality control
 Present: Machining quality is inspected and evaluated by quality control. Then, theoperator receives the corresponding measurement and reflect it to their machining jobs.
 Future: Machine tools will adjust their operation by themselves, while considering thevariance of quality as well as that of the operators and work piece property.
CyberSpace
CyberSpace

Physical Space

Physical Space

An organizational feedback loop
among the operator, quality control,
and production control.

Operatorʼs tacit knowledge aboutmachining process design and setup
is formulated for optimal machining.

Future, a real-time feedback loop in
the Cyber space, where theknowledge about quality control, andproduction control is formulated.

PresentFuture

5Case 3: Handling function deterioration and failure Present: Minimizing the failure occurrence by maintenance after failure or periodical
maintenance based on the knowledge of experienced workers.
 Future: Adjustment of machining operations and optimization of the timing ofmaintenance in order to maintain the productivity with the knowledge of tool vendors.
Cyber Space

Physical Space

Cyber Space

Physical SpaceThe Vendor prepares
information related
to available repair
based on trends andother information
shared in the normalstate.

Adjustment ofmachining operations
considering functional
deterioration.
Handling function deterioration
Measurement of a larger feedback involving
production control, maintenance, and themachine tool vendor.

Handling failure6Summary Investigated a mechanism to retrieve humanʼs real-time and on-site judgments fromnext generation machine tools, and their interfaces. To do so, an information modelingmethod to analyze such interfaces with use cases has been proposed.
 The committee members and WG members could work together and gain consensus
regarding the use cases and specifications of next generation machine tool interfaces.

Next step International cooperation toward realization of cyber physical manufacturing systems
enhanced with collaborative knowledge.
 Standardization of interface of machine tools as the core components of cyber-physicalmanufacturing systems is an example of cooperation, but not limited to this.

 Application of the proposed information modeling to visualization/evaluation of e.g.,
integration of supply chains and engineering chains and cyber security.

The report is available athttps://www.jmfrri.gr.jp/english/info/433.html

7