iSCAN Platform adapted for I4.0

The STREAM-0D (Simulation in Real Time for Manufacturing with Zero Defects) project, funded by the EU’s Horizon 2020 Framework Programme, began with the aim of creating an innovative control system, integrated in production lines, designed to: reduce product variability, increase the line flexibility, and eventually achieve a zero-defects manufacturing (ZDM) process.

Project partners, IES, who head up their R&D division in Dublin, were responsible for the development of a high-performance computing cloud and web-enabled database platform, providing secure collection, storage and accessibility of data to continuously update simulation models of the production lines.

Now, as the project enters the final stage, IES have reported some substantial advancements in its existing iSCAN platform to serve the specific needs of the industrial sector. Initially developed for use in the built environment as part of a suite of digital twin tools from IES, known as the Intelligent Communities Lifecycle (ICL), iSCAN is already being used to support the efficient operation of buildings and property portfolios. However, many of its existing features provided a robust starting point for the objectives of STREAM-0D, namely the ability to:

- Collate and analyse data from multiple sources and time-series;

- Integrate simulated virtual data based on physics principles and forecasting models, where data is absent or incomplete;

- Perform analytics for fault detection;

- Create bespoke dashboards and alerts.

While these features provided the foundations, substantial work was required to ensure the platform could suitably meet the needs of the industrial sector, where managing multiple lines to a high level of precision, is key.

First of all, this involved a complete restructuring of the underlying database, which previously worked at a 1-minute resolution. The new database now works down to a 1-second time step, with iSCAN normalising and collecting data across existing storage (e.g. SCADA), via streaming protocols such as MQTT. The information can then be visualized through dashboards, with users able to view the production status securely anywhere in the world.

To handle the large amount of data coming in from production lines, batching functionality was also added to the streaming data. This has helped to support the management of the continuous data stream, allowing insights to be viewed in the platform in near real-time. An API makes all of this data available to the rest of the STREAM-0D architecture, to track the entire production process and enable data management and predictive control based on the optimisation strategies developed by the STREAM-0D project partners.

As the industry 4.0 paradigm relies heavily on using data to achieve zero defect manufacturing, iSCAN now makes it possible to run automated analytics and data checks on models to detect deviations before they happen.

iSCAN can now store analytics results, sending warnings and status messages via dashboards (for manual control) or, when a condition is true, the platform can send custom data to a web service

(for automated control) to help industrial users implement line changes, based on forecasting models connected via the API.

IES also developed a recalibration process to prevent deviations in the simulation models developed by the STREAM-0D partners, to more accurately reflect the actual lines and improve overall accuracy in the system’s predictions.

Giulia comments: “We are very proud to have been a partner in this cutting-edge research project, applying our innovative iSCAN technology to enable industries to adjust their manufacturing processes in near real time, introducing smart decisions based on the forecast of the models. The project team have worked very hard to deliver true innovation over the time the project has been running. I believe these developments could be particularly beneficial to many of Ireland’s high-precision manufacturers, especially those working in the production of pharmaceuticals, medical appliances, and food products, and I’m excited to see the positive changes this technology will have on the manufacturing industry as a whole over the coming years.”

To find out more about the project, visit www.stream-0d.com