Omron Automation Americas Io T Industry 4 0

Omron Automation Americas – Io. T & Industry 4. 0 Solutions Updated: 10/8/2018

“If we had computers that knew everything there was to know about things—using data they gathered without any help from us—we would be able to track and count everything, and greatly reduce waste, loss and cost. We would know when things needed replacing, repairing or recalling, and whether they were fresh or past their best. ”

Consumer Io. T Industrial Io. T

Industrial Io. T How can we leverage available data from devices, systems, and people to help customers?

Industry 4. 0 • Optimizing production and manufacturing through data-driven automated decisions • Typically championed by OT department and Controls Engineers • Leverage machine and maintenance expertise in acting on only relevant data & information

Stay Practical If Controls/Motion/Robots help automate manual tasks… IIo. T & Industry 4. 0 technologies can help automate decisions

Omron is founding member of the Edgecross Consortium

K 6 CM Motor Condition Monitor • Calculates overall Motor Health & Degradation Level o Can monitor Current, Insulation Resistance, or Vibration/Temperature • Features: o Motor condition numeric value display o Alarm Bar in 3 colors – green, orange & red o Ether. Net/IP monitoring o Sample NA 5 HMI Screens

The Next Standard in Automation Controls – NX 1 ADVANCED MACHINE CONTROL

Improve Manufacturing Productivity Sysmac CPUs available with built-in data connectivity, through SQL Client or OPC-UA ü Data Security + Real Time Data Traceability Without compromising machine control ü Quality Control ü Advanced Machine Control

Safety & Industrial Io. T Improve operator safety & regulatory compliance by helping customers meet and maintain Performance Level (PL) • • • Must use “Well Tried” components (B 10 D) Assess Mean Time To Dangerous Failure (MTTFD) Maximize Diagnostic Coverage (DCavg) Select technical architecture by Category (Cat) Address Common Cause Failures (CCF) “If we had computers that knew everything there was to know about things…” Risk Assessment Performance Level Engineered Solution Audit

How can PL change? • • • Operating Time (T 10 D) Mechanical wear (B 10 D or MTTFD) Bypassing/override Environmental changes Part replacement or periodic maintenance

Omron Real-Time PL Calculation Gets ahead of upcoming regulations & audits, improve Environmental Health & Safety decisions Value: • Part of Omron Risk Assessment Ø Optional extra designed into Safety Control Panel • Monitor PL locally and choose next action locally • No network/enterprise infrastructure required

What is the Omron AI Controller? New solution that is uniquely able to Collect Analyze Utilize data on the Edge within a Sysmac controller, for the purpose of extending equipment lifecycle NY-Series NX-Series AI Application Component Configure & Startup

What does the Omron AI Controller do? Detecting outliers (failures, defectives) by learning from historical data in the machine 1) Issue definition 2) Cause identification Machine defects 3) Prepare sensors Method Human B occurs Material Based on failure impact and feasibility study of AI Controller utilization, define issue Machine Based on Cause and Effect Diagrams, identify cause of machine defect Based on the cause, add necessary sensors to machine Human Omron AI Controller fully covers the data collection, analysis, and utilization. 　Omron also offers startup support for the entire process. 4) Collect Data collection Pre-processing 6) Utilize 5) Analyze Storage Causal analysis, modeling X 1 Monitoring Visualization Control FB X 2 X 5 Machine X 3 Collect the raw data of machine Eliminate noise, create and collect the features of normal/abnormal state Store the characteristics data X 4 Create model data after causal analysis Status monitoring and control FB based on model data

Machine Learning Anomaly Detection Learn without being explicitly programmed

First Rele ase AI Application Components Pre-made Sysmac Library Function Blocks (FB) for… Mechanism Air Cylinder Ball Screw Conveyor Belt or Pulley Failure Type Machine event (failure causes) Operation stop Rubber Gasket broken (Rod/Piston) Over speed Speed Controller broken Over vibration Air Cushion broken Operation stop Contamination Operation stop Guide broken Operation stop Ball Bearings falling out Operation stop Contamination Vibration and low accuracy Contamination Operation stop Belt loosen Operation stop Belt broken Operation stop Pulley broken

So what? 1) Detect an issue has happened and do something about it immediately, reducing risk of bad parts or equipment damage 2) Leverage Omron’s technology and Data Scientist team instead of the customer figuring it out on their own 3) No extra infrastructure/connectivity cost for Fog or Cloud based solutions (typically managed by IT Department)

OEE Overall Equipment Effectiveness Value of Omron AI Controller Helps improve OEE at the machine level by increasing uptime = Uptime Operating time Stoppage Loss Availability Downtime x Performance Quality Net operating time Defect Loss Value operating time Performance Loss x Loss types Improved by AI Controller 1: Equipment failure 2: Changeover 3: Part replacement 4: Waiting for material 1: ✓ 2: 3: ✓ 4: 5: Minor stoppage/idle 6: Deceleration/slowing 5: ✓ 6: 7: Defect/modification 7: ✓

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