High-Tech Manufacturing Accelerator

Last updated:
12:17pm Sep 08, 2019

Overview

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:

High-Tech Manufaucturing Accelerator in action

What's New

(since the last release of High Tech Manufacturing Accelerator 2.1.0)

August 14, 2019, release of Intelligent Equipment Accelerator 3.0.0

  • Upgraded to latest SB10.4.4
  • Added two new metadata repository options: EBX and H2, as well as existing file
  • Added new historical data repository using H2
  • Added live Spotfire DXPs for Widgets, Power Plant, and ESP use cases
  • Restructure of source code hierarchy to separate apps and fragments
  • Added new Docker workspace to build containers for deployment
  • Added new application configuration to web dashboard
  • Added new Data Source module type for hot deploy of new data sources
  • Added new OPC UA demonstration to ESP use case
  • New decoupled architecture between components using message bus

Business Scenario

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.

Concepts

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.   

Technical Scenario

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.

Components

Software Minimum Version
TIBCO Streaming 10.4.4
TIBCO Streaming Artifact Management Server 1.4.4
TIBCO Spotfire Desktop 10.4.0
TIBCO Patterns Search 5.4.0
TIBCO Enterprise Message Service 8.5.0
TIBCO EBX 5.9.5

Documentation

Documentation Quick Start Guide is available by downloading the full Accelerator distribution package from here (license file for this component is here: license).

Back to main Accelerator page