Holonic Manufacturing Systems (HMS)

Edwin van Leeuwen

Chairman, HMS Board
 Holonic Manufacturing Systems (HMS)

Presentation Overview

X HMS Project

X Holonic Systems

X Industrial Testbeds

X HMS Phase 2
 Holonic Manufacturing Systems (HMS)

Basis of Holonic Systems

X Arthur Koestler
Autonomy
– The Ghost in the Machine, 1969
– Modeling of biological and social systems
X Holon
Free Agent Holon
– Greek word “holos” meaning whole
– Suffix “on” denoting a particle Slave Server
– Similar to AGENTS but always cooperative
– Self-contained unit capable of functioning Cooperativeness
independently but dependent on other units
X Holonic System
– Open modular
– Decision-making autonomy
– Cooperation by message passing and negotiation
 Holonic Manufacturing Systems (HMS)

Benefits of HMS

X Robustness to disturbances
X Human integration
X Availability
X Flexibility
X Scalability
X Coordination of distributed decisions
– Different times, locations, contexts, people
X Ideally suited for manufacturing and supply chain
enterprises
– Adaptive and distributed
– Can add intelligence with soft computing technologies
 Holonic Manufacturing Systems (HMS)

HMS Objectives

X Develop, market and support HMS compatible

devices, components, subsystems and support tools

X Design, implement, deploy and support HMS in

industrial applications

X Increase the understanding, systematization, and

acceptance of HMS concepts

X Support the development of international standards

which contribute to the achievement of HMS goals
 Holonic Manufacturing Systems (HMS)

HMS Project

• 5 Regions
Australia, Canada, EU, Japan, USA
X 30 Organizations
¾ Industry
ATOS, BHP Billiton, DaimlerChrysler, Fanuc, Rockwell Automation,
Toshiba, Yaskawa Electric
¾ R&D Laboratories
CSIRO, Fraunhofer IPA, NRC Canada, Profactor, VTT Automation
¾ Universities
Calgary, Connecticut, Hannover, Keele, KU Leuven, Osaka, SFU, Tokyo,
Vanderbilt

X Invested US$50,000,000
– Feasibility study 1991-93
– Phase 1: 7 work packages 1995-00
– Phase 2 : 4 work packages 2001-04
 Holonic Manufacturing Systems (HMS)

HMS Phase I and II

Operation

Distributed Production
Engineering Management

Education Business
& Planning
Training &
Operation
Manual
Supply-Chain
Work Integration
Management

Business & Enterprise

Integration
 Holonic Manufacturing Systems (HMS)

Holonic Manufacturing Systems

Presentation to ISC Board, May, 2002

Okinawa, Japan

Project 95003
Effective Date of Commencement
of the HMS Project: February 15, 1996
Phase I Termination: October 15, 2000
Phase II Commencement: October 16, 2000
 Holonic Manufacturing Systems (HMS)

HMS Vision
Manufacturing Challenge Required Characteristics
Flexibility
•Rapid delivery of
Agility
•customized Products in
Robustness
•competitive global markets

The Solution:
Autonomous
Cooperative
Modules
 Holonic Manufacturing Systems (HMS)

HMS Mission

Basic Technology and Organisation for Worldwide Goals:

·HMS Compatible Devices and Systems

·HMS in End-user Applications

·Understanding & Systematization of HMS

·International Standards
 Holonic Manufacturing Systems (HMS)

The Coordinating Partners of HMS

International
Coordinating
Partner
 Holonic Manufacturing Systems (HMS)

HMS Management Structure Phase I

BOARD
BOARD OF
OF
DIRECTORS
DIRECTORS (5)
(5)

Technical
Technical
Management
Management
Committee
Committee (10)
(10)

Consortium
Consortium
Partners
Partners

Systems Systems Holonic

Systems Systems Holonic Holonic
Holonic Holonic
Holonic Holonic
Holonic Holo-
Holo-
Architecture Operation Resource
Architecture Operation Resource Machining
Machining Fixturing
Fixturing HANDling
HANDling mobiles
mobiles
&& Eng’g
Eng’g Management
Management Unit
Unit Systems
Systems
(SYSENG)
(SYSENG) (SYSOP)
(SYSOP) (HoRMS)
(HoRMS) (HMU)
(HMU) (HOLOFIX)
(HOLOFIX) (HANDS)
(HANDS) (HMOB)
(HMOB)
 Holonic Manufacturing Systems (HMS)

HMS Meeting Attendance

10\01
05\01
10\00
6\00
2\00
10\99
6\99
2\99
10\98
6\98
2\98
10\97
6\97
2\97
10\96
6\96
2\96
10\95

0 5 10 15 20 25 30 35 40 45 50
 Holonic Manufacturing Systems (HMS)

Composition of Consortium Contributions (Man Months)

Phase I
Region Aust Canada EU Japan USA Total %

End User 110 80 184 169 - 543 23.85%

System
- - 107 - - 107 4.70%
Integrators
Vendors - - 61 351 24 436 19.15%
Research
211 - 345 - - 556 24.42%
Institutes
Academic
124 122 46 270 73 635 27.89%
Partners
Total 445 202 743 790 97 2277 100%

% 19.54% 8.87% 32.63% 34.69% 4.26% 100%

 Attendees

Pre

0
10
20
30
40
50
60
70
1000 Oaks Feasibility
Leuven Mar 93 (Kick-Off Meeting)
Kingston June 93
Melbourne Aug 93
Kobe Nov 93
Study

Lake Tahoe Feb 94

Feasibility

Herrsching May 94
Hamilton I. Nov 94
Denver Mar 95

HMS 1 Banff Oct 95

Cons.
Form’n

HMS 2 Kyoto Feb 96 (Kick-Off Meeting)

HMS 3 Helsinki June 96

HMS 4 Sydney Oct 96

HMS 5 Lake Tahoe Feb 97

HMS 6 Vienna June 97

HMS 7 Hawaii Oct 97

HMS 8 Vancouver Feb 98

Holonic Manufacturing Systems (HMS)

HMS 9 San Sebastian June 98

International Meeting Attendance

HMS 10 Mt Fuji Oct 98

HMS 11 Adelaide Frb 99

HMS 12 Stuttgart June 99

HMS 13 Orlando Oct 99

Full Scale Program

HMS 14 Torino Feb 00

HMS 15 Vancouver June 00

HMS 16 Japan Oct 00

HMS 17 USA May 01

HMS 18 Czech Rep. Oct 01

 Holonic Manufacturing Systems (HMS)

Investment by Partners in million US$ Phase I

30

3 Pre-feasibility Study

10 Feasibilty Study
3.8
Interim Period

Full-scale Program (I and II)

 Holonic Manufacturing Systems (HMS)

HMS Regional Contributions

Man-Month by Organisation type

28% 24%
End Users
System Integrators
5% Vendors
Research Institutes
Universities

24% 19% Man-Month by Region

4% 20%

34% 9%

33%
 Holonic Manufacturing Systems (HMS)

HMS Work Packages

±WP1 System Architecture and Engineering

±WP2 System Operation

±WP3 Holonic Resource Management

±WP4 Holonic Machining Unit

±WP5 Holonic Fixturing Station

±WP6 Holonic Handling System

±WP7 Holomobiles
 Holonic Manufacturing Systems (HMS)

HMS - Work Package Duration and Effort

Wk PEG
Pkg 96H1 96H2 97H1 97H2 98H1 98H2 99H1 99H2 00H1 00H2

165 ManMonth
SysEng
232 ManMonth
SysOp
588 ManMonth
HoRMS
313 ManMonth
HMU
181 ManMonth
HoloFix
477 ManMonth
HANDS
184 ManMonth
Hmob
 Holonic Manufacturing Systems (HMS)

HMS - Major Accomplishments

WP1/1: HMS Architecture Model

WP1/2: IEC6-1499 function block Holonic elements
http: www.holobloc.com

WP2/1: Reliable communication protocol

specification
WP2/2: Knowledge representation and
interpretation for resource allocation

WP3/1: Part-oriented control models of engine

manufacturing systems
WP3/2: Simulation study of holonic maintenance
scheduling in steel production
 Holonic Manufacturing Systems (HMS)

HMS - Major Accomplishments

WP4/1: Control Architecture of Machine Tool

Holon
WP4/2: System architecture of manufacturing
preparation system
WP4/3: Holonic process planning

WP5/1: Cooperation algorithm for workpiece

identification - development of sensor
holon
WP5/2: Algorithm for workpiece manipulation
system for fixturing
WP5/3: Design of the Holonic Fixturing Station
 Holonic Manufacturing Systems (HMS)

HMS - Major Accomplishments

WP6/1: Motion control methods for co-operating

robots
WP6/2: Communication interface and protocol of
sensor holons

WP7/1: Simulations: Holonic Motor Block

Assembly Line; Holonic AGV Material
Flow for Engine Assembly Line
WP7/2: Wireless Communivation Modules
WP7/3: Acceptance of Holonic line configuration
proposal by Daimler-Chrysler
 Holonic Manufacturing Systems (HMS)

ACCOMPLISHMENTS TO HMS GOALS

Components
WP2/1 Comms protocol
WP2/2 Resource Allocation Subsystems
WP4/3 Process planning
WP5/1 Sensor holons
Tools
WP6/2 Sensor holon protocols
WP7/2 Wireless comms.

WP1/1 HMS architecture Understanding

Support of
WP4/1 Control architecture
WP5/3 Holonic fixturing station
WP6/1 Co-operating robots
End-user
WP3/1 Part-oriented control Systematization Systems
WP3/2 Holonic maintenance
WP7/1 Holonic engine
production
WP7/1 Holonic material flow
WP7/3 Industrial acceptance WP1/2 IEC 61499
Standardization
 Holonic Manufacturing Systems (HMS)

Phase 1 Work Packages

X WP1 Systems Architecture and Engineering

X WP2 Systems Operation
X WP3 Holonic Resource Management
X WP4 Holonic Manufacturing Unit
X WP5 Holonic Fixturing
X WP6 Holonic Handling Systems
X WP7 Holomobiles
Completed February 2000
 Holonic Manufacturing Systems (HMS)

Phase 1 Industrial Projects

X Engine Assembly (DaimlerChrysler, IPA - Germany)

X Robotic Shot Blasting (Blastman Robotics, VTT -

Finland)

X Electric Motor Assembly (Toshiba, Hitachi, Fanuc,

Yaskawa - Japan)

X Electronic Assembly (Alcatel, ATOS - Belgium, Italy)

X Engine Machining (GM Holden - Australia)

 Holonic Manufacturing Systems (HMS)

HMS CONSORTIUM - Phase II

Phase I Results

PHYS.
PHYS. SUBSYSTS
OP’N
& OP’N

VALIDATION

SUBSYSTS
ARCH. &

and
ARCH.

CERTIFICATION

FRAMEWORK
FRAMEWORKDEV’T
DEV’T

FRAMEWORK
FRAMEWORK

Demonstrator
Demonstrator C
C
Demonstrator
Demonstrator B
B
Demonstrator
Demonstrator A
A
 Holonic Manufacturing Systems (HMS)

Phase 2 Work Packages

X Holonic Control Devices

– technical manufacturing equipment level
X Holonic Production Sites and Physical
Equipment
– manufacturing work cell level with multiple devices
X Holonic Production Execution Systems
– scheduling and control of Holonic Manufacturing Systems
at factory and supply chain levels
X Holonic Man-Machine and Emulation Systems
– virtual manufacturing and supply chain environment to
create test-beds for holonic system implementations
 Holonic Manufacturing Systems (HMS)

Conclusions
X Began with an abstract concept of holons
X Phase 1 – developed foundation for generic technologies
X Phase 2 – demonstrating potential for distributed systems
– Physical equipment
– Manufacturing work cells
– Factories
– Supply chains
X International acceptance of holonic system architectures
– Cooperating with FIPA to develop standards
X HMS provides
– capability to integrate manufacturing and supply chains
– offers migration path from legacy systems to fully
distributed manufacturing systems.