Industry 4.1

1 Cover

2 Series Page IEEE Press 445 Hoes Lane Piscataway, NJ 08854 IEEE Press Editorial Board Ekram Hossain, Editor in Chief Jón Atli Benediktsson Xiaoou Li Jeffrey Reed Anjan Bose Lian Yong Diomidis Spinellis David Alan Grier Andreas Molisch Sarah Spurgeon Elya B. Joffe Saeid Nahavandi Ahmet Murat Tekalp

3 Title Page

4 Copyright Page Copyright © 2022 by The Institute of Electrical and Electronics Engineers, Inc. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per‐copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750‐8400, fax (978) 750‐4470, or on the web at www.copyright.com . Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748‐6011, fax (201) 748‐6008, or online at http://www.wiley.com/go/permission . Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) 762‐2974, outside the United States at (317) 572‐3993 or fax (317) 572‐4002. Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic formats. For more information about Wiley products, visit our web site at www.wiley.com . Library of Congress Cataloging‐in‐Publication Data is applied for Hardback: 9781119739890 Cover Design: Wiley Cover Image: © Fan‐Tien Cheng

5 Editor Biography

6 List of Contributors

7 Preface Overview and Goals Overview and Goals The current Industry 4.0 related technologies emphasize on productivity improvement but not on quality enhancement; in other words, they can only keep the faith of achieving nearly Zero‐Defects (ZD) state without realizing this goal. The key reason for this inability is the lack of an affordable online and real‐time Total Inspection technology. By adopting the Automatic Virtual Metrology (AVM) that has been certified with the invention patents from six countries (Taiwan ROC, USA, Japan, Germany, China, and Korea) developed by the research team of Fan‐Tien Cheng, the Editor and main author of this book, ZD can be achieved as AVM can provide the Total Inspection data of all products online and in real time. A defective product will be discarded once it is detected by AVM; in this way, all of the deliverables will be ZD. Further, the Key‐variable Search Algorithm (KSA) of the Intelligent Yield Management (IYM) system developed by our research team can be utilized to find out the root causes of the defects for continuous improvement on those defective products. As such, ZD of all products can be achieved. Therefore, once AVM and IYM are integrated into the successfully developed Industry 4.0 platform constituting of Internet of things (IoT), CPS, big data analytics, and cloud computing, the state of ZD can be realized, which is defined as Industry 4.1 by Fan‐Tien Cheng. The concepts of Industry 4.1 were disclosed in IEEE Robotics and Automation Letters in January 2016. To realize and promote Intelligent Manufacturing, National Cheng Kung University (NCKU) established the Intelligent Manufacturing Research Center (iMRC) with Professor Fan‐Tien Cheng being its Director. Based on the platform of Advanced Manufacturing Cloud of Things (AMCoT) that won IEEE Conference on Automation Science and Engineering (CASE) 2017 Best Application Paper Award, iMRC integrates cross‐disciplinary research resources, utilizes various Intelligent‐Manufacturing related technologies, and implements Intelligent Manufacturing services [including AVM, IYM, Intelligent Predictive Maintenance (IPM), …, etc.] to develop the so‐called Intelligent Factory Automation (iFA) System Platform. Through implementing the iFA System Platform to the manufacturing tools and production lines of high‐tech (e.g. semiconductor, TFT‐LCD, and solar cell) and traditional industries (e.g. machine tool, aerospace, blow molding machine, and carbon fiber), ZD of all products as well as highly efficient and flexible intelligence capabilities (single‐machine intelligence, production‐line intelligence, and global‐fab intelligence) can be accomplished for improving the competitiveness and profits of all Intelligent‐Manufacturing related industries. Organization and Features Organization and Features To promote Intelligent Manufacturing and carry out the vision of Industry 4.1, our research team decided to include the survey and introduction of Intelligent Manufacturing, as well as the intact concept and the core technologies of Industry 4.1, along with the successful cases of iFA implementation for Industry 4.1 in different industries all in this book. This book contains 11 chapters in total. Chapters 1 – 5 describe the evolution of automation and the development strategy of Intelligent Manufacturing and introduce the mandatory components and fundamental technologies for constructing Intelligent Manufacturing. Chapter 6 introduces the overall concept of iFA integrated by the AMCoT framework with pluggable modules of AVM, IPM, and IYM intelligent services. Two versions of the iFA System Platform are provided for different business models. Chapter 7 illustrates the AMCoT framework for constructing the advanced cloud manufacturing platform. Chapters 8 – 10 address the principles and implementation of AVM, IPM, and IYM, respectively. Finally, the actual Intelligent‐Manufacturing implementation and application cases adopting all the techniques mentioned above in seven industries, including flat panel display, solar cell, semiconductor, automobile, aerospace, carbon fiber, and blow molding, are presented in Chapter 11 . Moreover, all the major patents related to AMCoT, AVM, IPM, and IYM are listed in Appendices 7.C, 8.C , 9.C , and 10.C , respectively. Fan‐Tien Cheng Life Fellow, IEEE Chair Professor, NCKU Director of Intelligent Manufacturing Research Center (iMRC), NCKU July 2021

8 Acknowledgments

9 Foreword

10 1 Evolution of Automation and Development Strategy of Intelligent Manufacturing with Zero Defects 1 Evolution of Automation and Development Strategy of Intelligent Manufacturing with Zero Defects Fan‐Tien Cheng Director/Chair Professor, Intelligent Manufacturing Research Center/Institute of Manufacturing Information and Systems, National Cheng Kung University, Tainan, Taiwan, ROC 1.1 Introduction 1.1 Introduction The evolution of automation from Industry 1.0 to 3.0 as well as e‐Manufacturing, which is the predecessor of Industry 4.0 is described in this chapter. Then, the core technologies of Industry 4.0 and the concept of mass customization are presented. After that, the concept of Zero Defects (ZD), which is the vision of Industry 4.1, is introduced. Finally, the five‐stage strategy of yield enhancement and ZD assurance is proposed in this chapter.