High-Tech Manufacturing Accelerator
Gather real-time insights into manufacturing systems with TIBCO's High Tech Manufacturing Accelerator. Capture sensor telemetry and apply validations and rules within a configurable equipment hierarchy. Monitor equipment status, part production, and compute Overall Equipment Effectiveness (OEE), providing intelligence sooner to enable actions to optimize production.
TIBCO Spotfire® TIBCO® Live Datamart TIBCO StreamBase®
TIBCO StreamingArtifact Management Server
TIBCO Spotfire Desktop
TIBCO Patterns Search
TIBCO Enterprise Message Service
TIBCO Component Exchange License
The High Tech Manufacturing Accelerator contains components to allow monitoring of production line performance against established metrics using Overall Equipment Effectiveness (OEE). It also also caputres data feeds from sensors on production equipment, validates the feeds, and evaluates the data against configurable business rules. It also includes components to visualize all these activities in a custom web dashboard, allowing operators to take corrective action when production issues are identified.
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High-Tech Manufacturing Accelerator
The High Tech Manufacturing Accelerator provides a reference architecture and code assets for building telemetry monitoring solutions inside of equipment hierarchies. It is primarily configuration-driven which allows a flexible object hierarchy based on the generic concept of Entities. Attached to these Entities are Devices which represent data producing sensors. The platform illustrates how capturing sensor telemetry along with production metrics can be used to give an overall high level view of production efficiency.
This video demonstrates the accelerator in action:
(since the last release of High Tech Manufacturing Accelerator 2.0.0)
December 6, 2018, release of High Tech Manufacturing Accelerator 2.1.0
- Upgraded to latest SB10.4.0
- Added new Autoencoder model and DXP to power plant case
- Changed all communication between Event Manager and Simulator to use JMS
- Changed how modules are deployed from extension point to containers with registry service and management through the UI
- Added ability to control execution order of validations, rules, statistics in UI
- Change how data is passed to actions using new tuple-to-dictionary and dictionary-to-tuple functions
Modern factories are populated with complex, expensive equipment. Manufacturers want to extract the greatest value from their factory equipment by maximizing equipment uptime, product throughput and quality and minimizing cycle times. Identifying bottlenecks in processing, taking proactive action in response to developing situations, and increasing operational system awareness are all key themes in sensor-driven manufacturing monitoring.
The High Tech Manufacturing Accelerator has a generic data model that is configuration driven. At the top level there are two main concepts:
Devices -- are anything that produce a stream of data. Also known as sensors. Typically produce data triplets at high frequency, consisting of a unique identifier, a timestamp, and a data value. Devices are attached to a single Entity, but an Entity can have multiple Devices.
Entities -- are anything else. This can be factories, production lines, equipment, aircraft, buses, ovens, drilling rigs... anything. Organized into hierarchies, one entity may have a single parent, but multiple children.
To help with configuration, the accelerator also supports Templates and Instances.
Instances -- are physical example of a Device or Entity, equivalent in object-oriented programming to an Object Instance. They are linked to a single Template, have a physical location, and a unique identifier like a serial number.
Templates -- definition of common properties for all Instances of a given Template, equivalent in object-oriented programming to a Class. May also be known as a type. Will not have a physical location or a unique identifier like a serial number (but could be a unique model number).
So this configuration looks like this:
In addition, users can configure Modules which link to physical EventFlow application modules implementing specific business rules. These may be implemented as Validation Modules, Cleansing Modules, Rule Modules, and Statistic Modules. These modules are then linked to Devices and Device Templates so they are called during the processing of data from these data sources.
The accelerator captures data feeds from configured Devices as readings or summaries. It also captures data feeds for status and attribute changes, as well as part produced and part summary messages. Combining all this information together it computes metrics and publishes alerts in response to configured business rules.
Benefits and Business Value
Most equipment today has connected sensors used to monitor and control the process. We can use the streaming data from these sensors, combined with context information from MES and other systems, to gain a complete real-time view of all manufacturing operations in order to rapidly resolve current issues and intervene to address preventable problems before they occur.
Factories, lines, equipment and streaming sensor data can be monitored in real-time. Rules and models can be employed that identify equipment, processes & product needing immediate attention. They can indicate both what is happening now and predict what will happen in the future. Dashboards can be updated continuously to visualize the current status and alerts can be pushed to provide targeted notifications. And finally, once monitoring has identified issues, analyses can automatically be kicked off to help diagnose the causes of problems.
The accelerator demonstrates real-time monitoring and alerting for a manufacturing use case. A simple entity hierarchy involving factories, production lines, and equipment is modelled, along with various device sensors attached to the equipment. Various validations are performed, some simple rules executed, and various statistics generated from the sensor data.
A simulator can then be run which will send through 10 sensor readings per second, per device. Some of the devices will monitor the data stream for values that exceed a configured maximum and then raise an alarm when this happens more than 5 times. The simulator will send status down messages due to obstruction, failures and material shortages. It will also send part produced messages on appropriate intervals. This information is used to compute the Overall Equipment Effectiveness at the production line and factory level.
At the heart of the accelerator is the Event Manager which is implemented using StreamBase. This is a series of EventFlow applications that receive Reports from various sources and perform the required business logic. The Event Manager includes extension points for validations, cleansing, rules, and statistics that allow users to configure their own logic modules and attach them to the data stream.
As data flows through the system, it is passed through to a real-time datamart implemented using Live Datamart and displayed on a real-time dashboard implemented using the LiveView JS API and a fully custom HTML5 application. This application is also used by administrators to configure the entity and device hierarchy, and attach logic modules to data flows.
TIBCO software products and versions used:
|TIBCO Streaming Artifact Management Server||1.4.0|
|TIBCO Spotfire Desktop||10.0.0|
|TIBCO Patterns Search||5.4.0|
|TIBCO Enterprise Message Service||8.4.1|
Documentation Quick Start Guide is available by downloading the full Accelerator distribution package from here .
License file for V2.x of this component is here: license.
License file for V1.x of this component is here: license.