IPC Smart Factory Standards - Manufuture...
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IPC Smart Factory Standards Powering Industry 4.0 David Bergman VP Standards & Training, IPC Manufuture October 2017
Transcript of IPC Smart Factory Standards - Manufuture...
IPC Smart Factory StandardsPowering Industry 4.0
David Bergman VP Standards & Training, IPC
Manufuture October
2017
Our Mission
IPC is an industry association supporting electronics manufacturing globally and dedicated to the competitive
excellence and financial success of its member companies worldwide.
Founded in 1957 as the Institute of
Printed Circuits
Six Founding Member Companies were
dedicated to growing the Printed Circuit Market
History
Who Do We Serve? 4300+ Global members
Worldwide Locations
USA (1957)Bannockburn, IL (headquarters)
Atlanta Georgia
Taos, NM
Washington DC
India (2010)Bangalore
Europe (2004)Brussels, Tallinn
Stockholm, MoscowChina (2002)Qingdao, Shanghai, Shenzhen,Beijing, Suzhou, Chengdu
SE Asia (2012)Bangkok
Members Blanket Electronic Manufacturing Supply Chain
PCB Manufacturers
EMS Companies
Suppliers
OEMs
Government/Academia
10%9%
23%
25%
34%
How Does IPC Strengthenthe Industry?
• Coordinates global collaboration on the development of industry standards
• Provides standards training
• Conducts and shares market research
Standards
How do you communicate with your customers?
With your suppliers?
IPC-A-600
IPC-TM650IPC-9691
SubtratesIPC-4101, 4104,
4202, 4203,
4204
IPC-6011, 6012,
6013, 6017IPC-A-610
J-STD-001
98509853AOI
NEW!
IPC-A-620 IPC-7711/21
IPC-4101, 4104,
4202, 4203,
4204
Assy MtrlsJ-STD-004J-STD-005
IPC-HDBK-005J-STD-006
IPC-SM-817IPC-CC-830HDBK-830
……
ComponentsJ-STD-020J-STD-032J-STD-033IPC- 9501IPC- 9502
……
IPC-1751IPC-1752
laminates PCB EMS
SMEMA
OEM
Third-party LAB
Components
Solder Flux
Cleaner
Assembly
materials
Components
Supply Chain Management
History of IPC in Intelligent Manufacturing
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Printed Circuit Board Intelligent Data
IPC-D-350 Printed Board Description in Digital Form; Technical
Content Identical to IEC-61182-1
Rev D 7/92Rev C 10/85Rev B 8/77Rev A 2/75Orig. 8/72
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Factory Automation
Merged with Surface Mount Equipment Manufacturers Association 1998
• SMEMA 1.2. The purpose of this standard is to provide an equipment interface specification for board transfer manufacturing systems of surface-mounted printed circuit boards.
• IPC-2531 Standard Recipe File Format Specification, originally published in 1999. The intent of this specification is to provide a standard method for developing process control files used by electronics manufacturing equipment. Process control files (often referred to as recipes) provide the instruction sets used by assembly equipment to accomplish specified tasks.
• CAM-X IPC-2541 Generic Requirements for Electronic Manufacturing Shop Floor Equipment Communication Orig. 10/01. This standard establishes requirements and other considerations for the interchange of information between electronic manufacturing software equipment and factory information systems.
IPC Confidential13
IPC Confidential14
What Is “CFX”?
Trigger: A Critical Mass of “Pain”
• Challenges of Industry 4.0 / smart / digital factories
• Difficulties to acquire live manufacturing data
• Multiple redundancy of effort of data capture
• Time for “IoT” style communication vs. acquisition!
• Task Group is named: “Connected Factory Initiative”
• Standard will be named “Connected Factory Exchange” (CFX)
• Committee Chairs:
Software Provider
Jason Spera
CEO
Aegis Software
What Is “CFX”?
Tier-One Manufacturer
Mahi Duggirala
Director Enterprise Solutions, IT
Flextronics
Machine Vendor
Marc Peo
President
Heller Industries
What Is “CFX”? Connected Factory Initiative: Task Group
• Aegis Software - Horsham PA
• Aegis Software – UK
• ASM Assembly Systems - Suwanee GA
• ASYS - Dornstadt Germany
• AT&T - Park Ridge IL
• AT&T Services, Inc - Durham NC
• Cimetrix Inc. - Midvale UT
• Cogiscan Inc. - Bromont QC Canada
• CYTIot, Inc. - San Mateo CA
• Essemtec AG - Aesch Switzerland
• Europlacer North America - Tampa FL
• FlexLink Systems, Inc. - Allentown PA
• Flextronics International - San Jose CA
• Fuji America Corporation - Vernon Hills IL
• Fujitsu Network Communications - Richardson TX
• Heller Industries Inc. - Florham Park NJ
• Jabil Circuit, Inc. (HQ) - Saint Petersburg FL
• Juki Automation Systems, Inc. - Morrisville NC
• Juki Corporation - Tokyo Japan
• Keysight Technologies - Loveland CO
• Keysight Technologies - Singapore Singapore
• KIC
• Mentor Graphics (Ireland) Ltd - Shannon Ireland
• Mentor Graphics-Valor Divison - Rancho Santa Margarita
• Microscan Systems Inc. - Renton WA
• MIRTEC Corporation - Oxford CT
• Miyachi Unitek Corporation - Monrovia CA
• Mycronic Technologies AB – Taby
• Northrop Grumman Corporation - Baltimore MD
• Omron Electronics LLC - Hoffman Estates IL
• Samsung C&T Automation, Inc. - Irvine CA
• Samsung/Hanwha - Seongsan-gu South Korea
• Trans-Tec America - Chandler AZ
• Universal Instruments Corporation - Conklin NY
• Viscom Inc. - Duluth GA
What Is “CFX”?
CFX Mission:
• Create a single, common standard for data exchange (plug & play)
• Enable modern, smart, digital, computerized Industry 4.0 solutions
• Eliminate waste & enable value creation throughout the industry
• Be accessible to companies in all sizes and sectors
CFX is the IoT standard for assembly manufacturing
What Is “CFX”?
CFX Mandate:
• “Plug and play” IoT communication standard
• Bi-directional exchange of information
• Connect every process, automated,
semi automated & manual
• Inclusive of bespoke processes, such as
functional test
• Adaptable for new automation and robotics
Plug
and playBi-directional
Connected Inclusive Adaptable
Introduction to
The IPC CFX Standard
Communication
Protocol
Language
Content
Content is Encoded and
sent using the Protocol
CFX Architectural Overview
CFX Principles: The search for modern IoT technology
CFX Architectural Overview: Communication Protocol
• Baseline Transport Protocol:
• Research:
• Months were spent to find the best protocol solution considering different viewpoints used: (scalability, failsafe, mission-critical data, IT friendly)
• Decision: AMQP v1.0
• Event data needs to be sent reliably to potentially many users (broadcast)
• Minimize the communication overhead for machines and processes
• Slight delays are not seen as critical
• Suitable also for point to point data (e.g. commands, requests)
Highlights:
• Established standard with built-in security
• Omni-directional
• Open source brokers available
• Equipment vendors are insulated from the
complexities of routing etc.
• Ease of development / implementation
Test Equipment
Enterprise
Software Systems
Automated
Material Handlers
Host or
Broker
Process &
Assembly Machines
AMQP 1.0 Flexible Message Transfer Protocol
Encoding By JSON
Highlights:
• Very light encoding format
• Easy “upgrade” from XML
• Libraries available in all development
platforms
• Simple to use
• Modern & popular
CFX Content Definition
CFX Content – The “Lego Brick” Approach
The Challenge:
• There are a wide range of complex processes:
• Assembly, placement, test, printing, marking, routing, soldering, bending, repairing, programming, packing etc.
• Many “hybrid” processes exist:
• e.g. Placement machine with optical inspection
• Who knows what new processes will come…
CFX Content – The “Lego Brick” Approach
The Solution:
• Break every process down into distinct components (bricks)
• Every process / operation can then be “built” by the combination of appropriate bricks
• New processes can be defined without the need to update the standard
• Applies to many types of assembly and other processes, including business, transactional, robotics, electro-mechanical etc.
=
CFX “Brick” Culture
PCB Arrives
Stop / Start
Visual Check
PCB Leaves
Broken-down Process Constituents
Product Tracking
Asset Utilization
Material Traceability
AOI Closed Loop Application
CFX ExampleApplications
Material Trace
IPC CFX Standard & Industry 4.0
• IPC CFX:
• Designed for IoT Manufacturing, for everyone
• Electronics assembly, mechatronics, and beyond
• Secure, simple, standard
• Industry 4.0:
• The business case of manufacturing
• Computerizations control automation
• Connected machines, lines, factory, enterprise
1. CFX: The Connected Factory Exchange
2. How to be a part of the Smart Factory, Industry 4.0
What we learned:
IPC CFX standard timeline
Developer Toolkit to be donated as Open Source software Q4 2017
APEX MeetingsFeb 2017• Decide transport
mechanism
Q3 IPC meetingsSept 2017• Review content /
structure to date
ProductronicaNov 2017• Initial demos (planning)
APEX MeetingsFeb 2018• Results / examples of
trials
VotingExpected by Summer 2018
IPC CFX Standard & Industry 4.0
Thank-you!
Next Steps:• Please contact IPC if you have any comments or questions
David W. Bergman
Vice President Standards & Training
IPC - Association Connecting Electronics Industries
3000 Lakeside Drive Suite 105N
Bannockburn, IL 60015-1249 USA
www.ipc.org
Backup slides
IPC Confidential32
What is Industry 4.0?
What is
IND
US
TR
Y
What is Industry 4.0?
Business Perspective:
• German Government Inspiration
• Small / medium enterprise initiative
• Manufacturing close to the market
• No distribution chain business case
• Flexible “build to order”, but mass
production efficiency
Technical Perspective:
• Computerization of automated processes
• Computerized, live decision-making, not just
a single solution
• Use of live data in computerizations
• Many sources, many consumers
What is Industry 4.0?
Values & Benefits:
• For Manufacturers:
• Lower-cost, flexible manufacturing
• Re-shoring opportunity to reduce global risk
• For Machine Vendors:
• More efficient “connected” automation
• Reduce the number of “MES Interfaces”, to one
• Value creation opportunity for Industry 4.0
• For Solution Suppliers & IT:
• Computerized decision-making solutions of many
types
• Focus on added value software development
Root Level 1 (Topic) Level 2 (Sub-Topic) Level 3 (Sub-Sub Topic)
CFX Production
AssemblySMT Assembly
THT Assembly
Test and InspectionPCB Paste Inspection
PCB Inspection
Application
Solder Paste Dispensing
Solder Dispensing
Coating
ProcessingThermal Processing
Cleaning
Casting and Molding
Machining
Forming
Loading and Unloading
Packing
CFX Message Name Architecture
Root Level 1 (Topic) Level 2 (Sub-Topic) Level 3 (Sub-Sub Topic)
CFX
ResourcePerformance
SMT Placement Performance
THT Inserter Performance
Solder Paste Printer Performance
Dispenser Performance
Reflow Oven Performance
Sensor Identification
Materials
Storage Automated Storage
Management MSD Management
Consumption
Transport
Information
Unit Validation
Work Order Management
Production Scheduling
Quality Management
CFX Message Name Architecture
Color Coding:
Green: Publish
Yellow: Consume
Blue: Publish & Consume
Examples Of CFX Message “Brick” Mapping
Example 1: Simple SMT Placement Machine
Color Coding:
Green: Publish
Yellow: Consume
Blue: Publish & Consume
Examples Of CFX Message “Brick” Mapping
Example 2: Intelligent SMT Process
Color Coding:
Green: Publish
Yellow: Consume
Blue: Publish & Consume
Examples Of CFX Message “Brick” Mapping
Example 3: Stencil Printer with SPI
Color Coding:
Green: Publish
Yellow: Consume
Blue: Publish & Consume
Examples Of CFX Message “Brick” Mapping
Example 4: MES System
CFX Message Types
Type Flow Recipient
Event Publish / Emit (Outbound Flow) Any Number of Recipients
Request Source -> Destination 1 Targeted Recipient
Response Destination -> Source Originator of Request
Broadcast Request Source -> Destination(s) Any Number of Recipients
Broadcast Response Destination(s) -> Source(s) Any Number of Recipients
Message Clarity: Different types of messages applicable for different purposes
CFX Message Envelope
Field Description
MessageNameName of the CFX message contained within the transmission (e.g.CFX.Production.WorkStarted)
Version The version number (revision) of this published standard
Timestamp The date and time when the occurrence of the event took place (ISO-8601)
UniqueID A globally unique ID identifying the “conversation” of messages
Source The CFX identification of the creator / publisher of this message
RequestID For Response type messages, it is the conversation ID of the Request
Message Integrity: Ability to keep track of discrete conversations, requests, commands
Structure of CFX Messages
• The messaging structure is based on a hierarchy of levels of “bricks”
• Each CFX message is named so as to know where in the structure it lies
Example message looks like “CFX.Materials.Consumption.MessageName”
Root: “CFX”
Level 1: “Topic” e.g. Materials
Level 2: Message e.g. Consumption
Level 1 CFX Message Names - Topics
• CFX:
• Root level - connection status, identification etc.
• CFX.Production:
• Affect or impact units of production as part of the production process
• CFX.ResourcePerformance:
• Activity of the production resource / production process
• CFX.Sensor:
• ID readers, temperature / humidity sensors etc.
• CFX.Materials:
• Consumption, spoilage, setup verification, storage
and movement
• CFX.Information:
• Factory control and management (routing,
schedule, quality) etc.
Application & Value Examples
• CFX Is a Key Ingredient For:
• Machine to machine data exchange
• Machines & processes to factory
• Factory systems to machines & processes
• Transactional events
Application & Value Examples: Machine - Machine
• Closed Loop Feedback:
• Dynamically change operation “A” using feedback “B”
• For example: AOI to SMD placement adjustment
• Machine Vendor / Lean Process Enhancement:
• Machine vendors provide closed-loop Industry 4.0 solutions
• Works with any other in-line equipment “off the shelf”
• Machine Vendor / Lean Process Enhancement:
• Lean Six Sigma live computerizations
• Enables control of any process, based on measurement
IND
US
TR
Y 4.0Applies to all processes,
not just machines…
Application & Value Examples: Processes - Factory
• “Big Data” Collection:
• Many different types and sources of data
• Collected, contextualized and analyzed
• Local & enterprise Business Intelligence
• Applications:
• Productivity, efficiency and OEE
• Reports, dashboards, alerts, opportunities to improve
• Planning, including capacity planning, flexibility
• Supply-chain control, JIT material delivery, resource management
• Traceability (IPC-1782)
Industrial Engineering & MES
taken to the next level
Application & Value Examples: Factory - Processes
• Operational Data:
• Engineering data (programs, documents etc.)
• “Poke-Yoke” control
• Material information (supply-form, vendor exception)
• Product data (production unit information)
• Applications:
• Automated changeover preparation
• Setup optimization
• Active quality management
Live & Real-time Process
optimization / Factory Control
POKA YOKE
(MISTAKE PROOFING)
Application & Value Examples: Transactional
• Automated Transactions:
• Stock purchase / material movement / back-flush
• Tool and machine maintenance
• Program / document setup
• Applications:
• Enhanced ERP / MRP
• Resource reservation & management
Error proofing critical
dependent transactions
