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Smart
Manufacturing
in Action
SHAI GERSHON – CONTEL
‫חדשות‬ ‫טכנולוגיות‬ ‫לרתום‬ ‫יודע‬ ‫חכם‬ ‫מפעל‬
‫נכסיו‬ ‫של‬ ‫הנצילות‬ ‫את‬ ‫לשפר‬ ‫בכדי‬
WHAT MAKE YOU SMART ?
‫תערובת‬ ‫מכון‬‫מילובר‬
‫במכון‬ ‫כבישה‬ ‫בקווי‬ ‫תפעולית‬ ‫התייעלות‬
‫הפרויקט‬ ‫ביצוע‬ ‫טרם‬ ‫המצב‬ ‫תאור‬
‫תערובת‬ ‫סוגי‬ ‫של‬ ‫רב‬ ‫מספר‬.
6‫המשלוח‬ ‫לתאי‬ ‫ומועברים‬ ‫התערובת‬ ‫את‬ ‫ומיצרים‬ ‫גלם‬ ‫חומר‬ ‫המקבלים‬ ‫מכבשים‬.
‫והעברתו‬ ‫הקו‬ ‫לריקון‬ ‫עד‬ ‫הגלם‬ ‫חומר‬ ‫מכניסת‬ ‫אחד‬ ‫מוצר‬ ‫סוג‬ ‫ליצר‬ ‫יכול‬ ‫הכבישה‬ ‫קו‬
‫המשלוח‬ ‫לתא‬.
‫כ‬ ‫הוא‬ ‫הכבישה‬ ‫בקו‬ ‫תערובת‬ ‫ליצור‬ ‫ממוצע‬ ‫זמן‬-6‫שעות‬.
‫בעיה‬-‫הכבישה‬ ‫קו‬ ‫ריקון‬ ‫לסיום‬ ‫עד‬ ‫חדש‬ ‫תערובת‬ ‫בסוג‬ ‫עבודה‬ ‫התחלת‬ ‫מתאפשרת‬ ‫לא‬
‫הקודמת‬ ‫מהתערובת‬.‫המכבשים‬ ‫של‬ ‫עבודה‬ ‫זמן‬ ‫לאיבוד‬ ‫גורם‬ ‫זה‬ ‫עבודה‬ ‫אופן‬,
‫כ‬ ‫בממוצע‬-2‫מכבש‬ ‫עבור‬ ‫ביממה‬ ‫עבודה‬ ‫שעות‬.
4
1
Product
PRESS
FINAL
GOODS
RAW
MATERIAL
‫הפתרון‬ ‫תאור‬
‫מקטעים‬ ‫לשני‬ ‫הכבישה‬ ‫קו‬ ‫חלוקת‬–‫הניתוב‬ ‫וקטע‬ ‫הכבישה‬ ‫קטע‬.
‫שונה‬ ‫תערובת‬ ‫סוג‬ ‫ייצרו‬ ‫והניתוב‬ ‫הכבישה‬ ‫קטע‬.
‫החיסכון‬-‫תערובת‬ ‫להתחיל‬ ‫ניתן‬ ‫הכבישה‬ ‫במקטע‬ ‫התערובת‬ ‫בסיום‬
‫הניתוב‬ ‫בקטע‬ ‫החומר‬ ‫לריקון‬ ‫בהמתנה‬ ‫צורך‬ ‫ללא‬ ‫חדשה‬.
5
‫מקטע‬
‫כבישה‬
‫מקטע‬
‫ניתוב‬
‫השדרוג‬ ‫לפני‬ ‫מצב‬
6
MODICON IO DROPS
DROP 2
DROP 3
DROP 4
MODICON – PLC + IO
PCIM
‫סימולציה‬ ‫מצב‬–‫קיים‬ ‫לבקר‬ ‫במקביל‬ ‫בלבד‬ ‫קריאה‬
MODICON IO DROPS
DROP 2
DROP 3
DROP 4
Ethernet/IP to
Modicon IO Scanner
Allen-Bradley - ControlLogix
MODICON – PLC + IO
PCIM
NEW HMI
‫סופי‬ ‫מצב‬–‫חדש‬ ‫בקר‬ ‫באמצעות‬ ‫הפעלה‬
8
8
MODICON IO DROPS
DROP RIO 2
DROP RIO 3
DROP RIO 4
Ethernet/IP to
Modicon IO Scanner
Allen-Bradley - ControlLogix
NEW HMI
Project Results
 30% production output improvement
 Energy costs reduction by more than 20%
NESHER – OT Software upgrade
6 Million
Ton Per
Year
2 stages process 12
‫טחינה‬ Grinding
GRINDING KLINKER
 80,000 data points (I/O)
 80 PLCs
 Legacy PCIM SCADA
 7000 operational Displays
 80 Clients
13
BIG DATA
ייצור מתקדם בפעולה - שי גרשון (קונטאל)
Technological upgrade
with new IIOT tools
FOR OPERATIONAL EXCELLENCE
standardization
 OBJECT LIBRARYS
 BETER UTILZATION
 EASIER MAINTANCE
 KNOWLEDGE TRANSPARENCY
ANALYTICS – FACTORY TALK ™
 BIG DATA ANYLTICS
 OT PORTAL
 EDIT AND PUBLISH PROCESS DATA AND TRENDS
 WEB BROWSER
 MOBILE DEVICES
 ONLINE DATA SIDE BY SIDE WITH HISTORICAL DATA
 PERFOMANCE KPIS
18
Self learning
STATISTICAL PROCESS CONTROL
 Dynamic updates of statistical boundaries
 Real time process alerts based on statistical rules
 KPIs
 Visual display of the process data
Photovoltaic power plant
IIOT application
 1000 ACRES @ WEST NEGEV
 180,000 SOLAR PANELS
 360 COMBINER BOXES
 36 AC/DC POWER INVERTORS
 900 CURRENT INDICATORS
 60 POWER METERS
 5 METHOROLOGICAL SITES
 TEMPRATURES, RADIATIONS, WIND, ETC.
 WATER TREATMENT SYSTEM
 HIGH VOLTAGE POWER TRANFORMERS
20
ייצור מתקדם בפעולה - שי גרשון (קונטאל)
So what make you smart ?
22
INDUSTRY 4.0 / IIOT
WHAT MAKE YOU SMART ?
ייצור מתקדם בפעולה - שי גרשון (קונטאל)
ייצור מתקדם בפעולה - שי גרשון (קונטאל)
MACHINE VISION
WHAT MAKE YOU SMART ?
ROBOTICS
WHAT MAKE YOU SMART ?
0
100
200
300
400
500
600
2015 2016 2017 2018 2019 2020
INDUSTRIAL ROBOTS- UNITS PER YEAR
ASIA EUROPE AMERICA
END TO LABOUR ARBITRAGE
ASIA
26%
EUROPE
40%
AMERICA
34%
2016 DENSITY- ROBOTS PER 10,000 EMPLOYEES
ASIA 63
EUROPE 99
AMERICA 84
Shai Gershon
CONTEL TECHNOLOGIES
054-9260353
SHAI@CONTEL.CO.IL
THNAK YOU
30

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ייצור מתקדם בפעולה - שי גרשון (קונטאל)

  • 2. ‫חדשות‬ ‫טכנולוגיות‬ ‫לרתום‬ ‫יודע‬ ‫חכם‬ ‫מפעל‬ ‫נכסיו‬ ‫של‬ ‫הנצילות‬ ‫את‬ ‫לשפר‬ ‫בכדי‬ WHAT MAKE YOU SMART ?
  • 3. ‫תערובת‬ ‫מכון‬‫מילובר‬ ‫במכון‬ ‫כבישה‬ ‫בקווי‬ ‫תפעולית‬ ‫התייעלות‬
  • 4. ‫הפרויקט‬ ‫ביצוע‬ ‫טרם‬ ‫המצב‬ ‫תאור‬ ‫תערובת‬ ‫סוגי‬ ‫של‬ ‫רב‬ ‫מספר‬. 6‫המשלוח‬ ‫לתאי‬ ‫ומועברים‬ ‫התערובת‬ ‫את‬ ‫ומיצרים‬ ‫גלם‬ ‫חומר‬ ‫המקבלים‬ ‫מכבשים‬. ‫והעברתו‬ ‫הקו‬ ‫לריקון‬ ‫עד‬ ‫הגלם‬ ‫חומר‬ ‫מכניסת‬ ‫אחד‬ ‫מוצר‬ ‫סוג‬ ‫ליצר‬ ‫יכול‬ ‫הכבישה‬ ‫קו‬ ‫המשלוח‬ ‫לתא‬. ‫כ‬ ‫הוא‬ ‫הכבישה‬ ‫בקו‬ ‫תערובת‬ ‫ליצור‬ ‫ממוצע‬ ‫זמן‬-6‫שעות‬. ‫בעיה‬-‫הכבישה‬ ‫קו‬ ‫ריקון‬ ‫לסיום‬ ‫עד‬ ‫חדש‬ ‫תערובת‬ ‫בסוג‬ ‫עבודה‬ ‫התחלת‬ ‫מתאפשרת‬ ‫לא‬ ‫הקודמת‬ ‫מהתערובת‬.‫המכבשים‬ ‫של‬ ‫עבודה‬ ‫זמן‬ ‫לאיבוד‬ ‫גורם‬ ‫זה‬ ‫עבודה‬ ‫אופן‬, ‫כ‬ ‫בממוצע‬-2‫מכבש‬ ‫עבור‬ ‫ביממה‬ ‫עבודה‬ ‫שעות‬. 4 1 Product PRESS FINAL GOODS RAW MATERIAL
  • 5. ‫הפתרון‬ ‫תאור‬ ‫מקטעים‬ ‫לשני‬ ‫הכבישה‬ ‫קו‬ ‫חלוקת‬–‫הניתוב‬ ‫וקטע‬ ‫הכבישה‬ ‫קטע‬. ‫שונה‬ ‫תערובת‬ ‫סוג‬ ‫ייצרו‬ ‫והניתוב‬ ‫הכבישה‬ ‫קטע‬. ‫החיסכון‬-‫תערובת‬ ‫להתחיל‬ ‫ניתן‬ ‫הכבישה‬ ‫במקטע‬ ‫התערובת‬ ‫בסיום‬ ‫הניתוב‬ ‫בקטע‬ ‫החומר‬ ‫לריקון‬ ‫בהמתנה‬ ‫צורך‬ ‫ללא‬ ‫חדשה‬. 5 ‫מקטע‬ ‫כבישה‬ ‫מקטע‬ ‫ניתוב‬
  • 6. ‫השדרוג‬ ‫לפני‬ ‫מצב‬ 6 MODICON IO DROPS DROP 2 DROP 3 DROP 4 MODICON – PLC + IO PCIM
  • 7. ‫סימולציה‬ ‫מצב‬–‫קיים‬ ‫לבקר‬ ‫במקביל‬ ‫בלבד‬ ‫קריאה‬ MODICON IO DROPS DROP 2 DROP 3 DROP 4 Ethernet/IP to Modicon IO Scanner Allen-Bradley - ControlLogix MODICON – PLC + IO PCIM NEW HMI
  • 8. ‫סופי‬ ‫מצב‬–‫חדש‬ ‫בקר‬ ‫באמצעות‬ ‫הפעלה‬ 8 8 MODICON IO DROPS DROP RIO 2 DROP RIO 3 DROP RIO 4 Ethernet/IP to Modicon IO Scanner Allen-Bradley - ControlLogix NEW HMI
  • 9. Project Results  30% production output improvement  Energy costs reduction by more than 20%
  • 10. NESHER – OT Software upgrade 6 Million Ton Per Year
  • 11. 2 stages process 12 ‫טחינה‬ Grinding GRINDING KLINKER
  • 12.  80,000 data points (I/O)  80 PLCs  Legacy PCIM SCADA  7000 operational Displays  80 Clients 13 BIG DATA
  • 14. Technological upgrade with new IIOT tools FOR OPERATIONAL EXCELLENCE
  • 15. standardization  OBJECT LIBRARYS  BETER UTILZATION  EASIER MAINTANCE  KNOWLEDGE TRANSPARENCY
  • 16. ANALYTICS – FACTORY TALK ™  BIG DATA ANYLTICS  OT PORTAL  EDIT AND PUBLISH PROCESS DATA AND TRENDS  WEB BROWSER  MOBILE DEVICES  ONLINE DATA SIDE BY SIDE WITH HISTORICAL DATA  PERFOMANCE KPIS
  • 17. 18
  • 18. Self learning STATISTICAL PROCESS CONTROL  Dynamic updates of statistical boundaries  Real time process alerts based on statistical rules  KPIs  Visual display of the process data
  • 19. Photovoltaic power plant IIOT application  1000 ACRES @ WEST NEGEV  180,000 SOLAR PANELS  360 COMBINER BOXES  36 AC/DC POWER INVERTORS  900 CURRENT INDICATORS  60 POWER METERS  5 METHOROLOGICAL SITES  TEMPRATURES, RADIATIONS, WIND, ETC.  WATER TREATMENT SYSTEM  HIGH VOLTAGE POWER TRANFORMERS 20
  • 21. So what make you smart ? 22
  • 22. INDUSTRY 4.0 / IIOT WHAT MAKE YOU SMART ?
  • 27. 0 100 200 300 400 500 600 2015 2016 2017 2018 2019 2020 INDUSTRIAL ROBOTS- UNITS PER YEAR ASIA EUROPE AMERICA
  • 28. END TO LABOUR ARBITRAGE ASIA 26% EUROPE 40% AMERICA 34% 2016 DENSITY- ROBOTS PER 10,000 EMPLOYEES ASIA 63 EUROPE 99 AMERICA 84