SOA in Manufacturing - MESA · PDF fileData Warehouse & eBusiness Supplier Production ... AAG...
Transcript of SOA in Manufacturing - MESA · PDF fileData Warehouse & eBusiness Supplier Production ... AAG...
www.mesa.org2008 North American Plant-to-Enterprise ConferenceSeptember 21-23, Orlando, FL
SOA in ManufacturingA Panel Discussion
Dave Noller Tim Thomasma Charlie Gifford
Mike Brooks Bryan Zigler
Strategic Initiatives
The following Strategic Initiatives of MESA International are associated with
this presentation: *
Lean ManufacturingQuality & Regulatory Compliance
Product Lifecycle Management (PLM)Real-Time Enterprise
Asset Performance Management (APM)* SOA is a horizontal technology and applies to all of these
Discussion Agenda
• Business issues driving change • Architecture and standards• Case Studies:
– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron
Discussion Agenda
• Business issues driving change • Architecture and standards• Case Studies:
– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron
• Lack of flexibility• Obsolete technology• Lack of system commonality across company
• High support costs• Evolving business models
Broadcast
WIPTrack
ProductionMonitoring
Scheduling
SCADA
ANDON
DataCollection
ReSequence
eKanban
Logistics
Suppliers
CorpSystems
OrderMgmt
Quality
ErrorProofing
AssetMgmt.
Requirements for Agility Are Forcing Change
• Poor asset utilization• Multitude of point to point integrations
• Various operating systems and languages
• Many device connections
Discussion Agenda
• Business issues driving change• Architecture and standards• Case Studies:
– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron
“Mfg 2.0” Defines the Need for “MES by Composition”
Source: Manufacturing 2.0: Service and Collaboration-Based Architectures for Manufacturing Right First Time—on demand AMR Research, 2007
AMR Research Manufacturing Exchange © 2007 AMR Research, Inc. | Page 8
EWIEWIQualityLIMSQuality
LIMSODSODS
MES
Manufacturing SOA: Foundation for Manufacturing 2.0
DBLogic
UI
MfgMDM
Security and Management
ODS EnterpriseApps
QualityLIMS EWI
Event/ActivityMonitoringOPM OI Ops
PortalMfg
ContentMfg Service
Registry
Transact Enrich Manage
Service Enablement Layer
MES ProductsAssets
ProcessesEtc.
DCS, PLC, RFID (OPC), Wireless Sensors
MES
Services Bus
Manufacturing Composite Apps
ScheduleOptimization
Track &Trace
RightFirst Time MES 2.0
Office Web 2.0
Asset Performance
Recipe Workbench
Governance
Tools (e.g., MC
E)
MCE = Manufacturing Composition Environment, OPM = Operations Process Management, OI = Operations Intelligence,LIMS = Laboratory Information Management System, EWI = Electronic Work Instructions AMR Research 2007
Standards Model for Manufacturing Solutions
• SOA provides a common framework for integration SOA is assisted by content standards, providing a common set of semantics / data content for integration
• OAGi, ISA-95, AIAG, STAR , JAMA, ODETTE….
• Standards groups including OAGi, ISA, OPC Foundation, Mimosa and WBF have been working to map and converge some of the existing standards (initial focus on OAGIS and ISA-95). This work is now sponsored by the OpenO&M group. OAGIS 9.2 includes results from this work.
Modeling (e.g. based on ISA-95) Adds Structure and Supports Data Exchange
Between Disparate Architectures
Firewall
Device Communications
Plant Communications Legacy Technologies (Sockets)TCP/IP – LAN
WS-I Compliant Web Services
Guaranteed DeliveryPub-SubSerial
EthernetOPC
InternetANX – Secure Channel Internet
SSL/Encrypted MessagingWS-I Compliant Web Services
Enterprise CommunicationsTCP/IP – WAN
WS-I Compliant Web ServicesBehind corporate firewall
Supply Chain Environment
Shop Floor
Plant Computer RoomOffice Automation
Enterprise Data CenterInternal Facing
ExtranetEnterprise Data Center
External Facing
Firewall
Firewall
InternetDMZ
ManufacturingSystems
PlantSystems
EnterpriseSystems
Middleware
EdgeComponents
Middleware
ISA Levels 0, 1, 2
ISA Level 3
ISA Level 4
Modeling(Transactions)
Modeling
Discussion Agenda
• Business issues driving change • Architecture and standards• Case Studies:
– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron
eHub at Ford – 2001 Initial Production Environment
eHub Production Environment
HPUXHPUX1a
Browser
Server
Plant
W2KW2K
NT 4 SP4NT 4 SP4
1a
1a
IIS BTS
4-Way
1b
Data Center DMZ Supplier
IIS,SOAPIIS,
SOAP
21a: Event to initiate trans (HTTP Post)
1b: Event to initiate BTS (ASP Submit)
1c: Store trans for later access/analysis2: Provide supplier access to trans
IIS BTS
4-Way
1b
Cisc
o Lo
cal D
irect
orC
isco
Loca
l Dire
ctor
SQL ClientSQL Client
SQL ClientSQL Client
Connect to IIS/BTS via HTTP
3
4. Allow supplier to set communication criteria
4
BTS = BizTalk ServerSOAP = Simple Object Access ProtocolIIS = Internet Information ServerOAG = Open Applications GroupBOD = Business Object Document
OAG BOD
OAGBOD
OAG BOD
2 load balanced 2-Ways
3: Push trans to supplier
firewall
4-Way, clustered (Active/Active)
DB instances:BTS1 BTS2
eSMART eQLS ePOSmon…
1c
4-Way, clustered (Active/Active)
DB instances:BTS1 BTS2
eSMART eQLS ePOSmon…
1c
Discussion Agenda
• Business issues driving change • Architecture and standards• Case Studies:
– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron
SOA has Allowed IBM to Create a Virtual Manufacturing
Enterprise….
• The various permutations and combinations carry with them many requirements for successful integration:
– pathways between all participants must be reliable and secure
– IBM must see all events as they occur
– IBM must collect all data as it is produced, at any source
– each participant must accept control from IBM sufficient for consistent product & process results
– each participant must have access to all necessary functions, even if not local/native to their environment
– pathways between participants must be dynamically flexible and possible to select in real-time via business rules
WaferFab
WaferTest
ModuleBuild
ModuleTest
IBM 200mm IBM 200mm IBM A IBM A
IBM 300mm IBM 300mm IBM B IBM B
Vendor A Vendor B Vendor C IBM C
Vendor C Vendor D Vendor C
Vendor E
Vendor F
Primary PathAlternate Path
ILLUSTRATIVE SCENARIO
where ‘Virtual’ means….
1.Standard integration of one or more heterogeneous mfg assets/systems
2.Convergence of all mfg assets/systems to a single interface to/from enterprise systems
3.Aggregation of data from all mfg assets to a single standard and integrated form
4.Management control of all mfg assets in real-time, defining control points, parameters and rules to enact in order to meet product requirements
SUPPLIER
VENDOR(S)
MES BACKBONE
CUSTOMER 1 CUSTOMER 2 CUSTOMER N
Fulfillment &Distribution
Supply/DemandPlanning
Finance &Costing
Data Warehouse &eBusiness
SupplierProductionMES/Asset
VendorProduction
MES/Asset 1
VendorProduction
MES/Asset N
2
134
MDI11
SUPPLIER
VENDOR(S)
MES BACKBONE
CUSTOMER 1 CUSTOMER 2 CUSTOMER NCUSTOMER 1 CUSTOMER 2 CUSTOMER N
Fulfillment &Distribution
Supply/DemandPlanning
Finance &Costing
Data Warehouse &eBusiness
SupplierProductionMES/Asset
VendorProduction
MES/Asset 1
VendorProduction
MES/Asset N
2
134
MDI11
(IBM)
Enterprise Systems
Mfg S
ite/Vendor S
ystems
Order Management WIP Tracking Broadcast - Print Broadcast - Device B2B Business System Interface Parts Verification Parts Traceability Parts Containment Record Defects Record Repairs Final Finish
Enterprise Services Bus
Wireless Business Systems End User Portals Suppliers .
Industry workbenches allow services to be quickly configured by production personnelinto a process workflow to support workstation logic
Manufacturing Services Pallet
Service Service Service Service
Service AdapterService
Process
Workflow
Services
Station LogicWorkflow
BPEL
Production Database
PLC
Services
Process Location 1
Automotive Assembly Example
PLC
Services
Process Location 2
Device Gateway Device Gateway
2findOrderupdateWIPStatusupdateLegacybroadcastOrder
New services, legacy
wrappers, orMES COTS
WIP Tracking Event
1Broadcast Order Data to device(s)
3
WIP Tracking Event
4
findOrderupdateWIPStatusupdateLegacybroadcastOrder
New services, legacy
wrappers, orMES COTS5
Broadcast Order Data to device(s)
6
Discussion Agenda
• Business issues driving change • Architecture and standards• Case Studies:
– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron
Semantic Layer is SOA Business Case
• Interoperability requires interfaces to be standardized. Only 5% of the interface is a function of the middleware.
• The other 95% is a function of the application semantics. (Gartner Group)
Application Integration Semantics
Messaging and Transport Services
95%
5%
OAGIS
Level 3: Manufacturing Operations
Level 4+: Enterprise
Level 5+: Inter-Enterprise
Levels 2, 1, 0: Machine / Plant Work
OPC: DA, HDA, A&EOMAC
Discrete Process
OAGIS
MIM
OSA
ISA-99
OPC
UA ISA-95
ISA-88B2MMLOAGIS
The Integration Evolution: OpenO&M™ Domain Map
F O U N D A T I O N
Hybrid
Let’s Talk about B2M Business Value
Open O&M Technical Applications and Methods being applied by Innovative Manufacturers, Vendors, and SIs
• 3M, Genentech, Kraft, FritoLay, GM, Tata Motors, Dow, DuPont, P&G, Pfizer, BP, Nestle, Masterfoods, BP, Chevron, Coors-Molson, Eli Lilly, InBev, Wrigley, Heineken, Lion Nathan, GE Health, J&J, SAB Miller, others
• Oracle, SAP, IBM, Tibco, Infor, others
• GE Fanuc, Rockwell, Wonderware/Invensys, ABB, Siemens, Honeywell, Citect, Werum, AspenTech, Kepware, others
• Atos Origin, Logica CMG, Ordina, EDS, AAG companies, Wipro, Maverick Technologies, Entegreat, ASECO, NNE Pharma, Wunderlich-Malec, others
Copyright @2007 AMR Research: All rights reserved.
Revenue Share Growth Opportunities: Emerging Economies
Top Revenue Producing Regions: 07 & 12
Capacity Realignment: Proximity to New Markets
Top Mfg./Sourcing Regions: 2007 & 2012
Copyright @2007 AMR Research: All rights reserved.
► We expected ONE-TO-MANY
PI-PCS ……SAP XI
SAP R/3 MM – PP-PI – QM
MESSystem X
Plant A,B,C ..
MESSystem Y
Plant M,N,..
MESSystem ..Plant ..
PLC PCSPLCPLC PLC
ISA-95/WBF standard (B2MML XML)
PCS PMYPPPSAP xMII
MESSystem X
Plant A,B,C ..
MESSystem Y
Plant M,N,..
MESSystem ..Plant ..
PLC PCSPLCPLC PLC
ISA-95/WBF standard (B2MML XML)
Site XSite X
Site XSite X
► It was more like MANY-TO-ONE(-to-many..)
ArlaTemplate
#1
ArlaTemplate
#2
ArlaTemplate
#3
Arla Foods: Motivation to use Open Standard Integration!
The Arla Food Costs ?Site 1 to 15
2003-2006 2007 2008
Specification
R/3 -config
MES-config
Testing +go-live
24x7
XI-config24x7
Specification
R/3 -config
MES-configTesting +
go-live
24x7
xMII-config24x7
R/3 -config
MES-configTesting +go-live
24x7
xMII-config24x7
Specification
Expensive ?? YES, integration is still complex and both procedures & structure is needed !!!
SOAEvolution
Message Queuing
Abstracts the connectivity
logic from the application
Message Brokering
Abstracts the connectivity + mediation logic from the application
Service Orientation
Reduces application to its core business
functions(i.e. a service)
Application Application
Degree of Flexibility and Reuse
Direct Connectivity
All connectivity, mediation and additional logic (e.g. conditional processing, routing) buried in the
application.
Application
Line
s of c
ode
Application Services
Mediation &additional logic
Additional Logic
Connectivity logic
Connectivity andmediation logic
Connectivity,mediation &
additional logic
Connectivity,mediation &
additional logic
Discussion Agenda
• Business issues driving change • Architecture and standards• Case Studies:
– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron
Boeing Vision “Design Anywhere, Build Anywhere”
BOEINGFACTORY
BOEINGFACTORY
Enable Lean Interoperability betweenDesign and Execution
BOEINGFACTORY
BOEINGFACTORY
SUPPLIERPORTALBPN
Sort – Process Modeling– Sort business processes and activities operate value streams
• Simplify – Common Processes– Simplify things and derive potential services– Eliminate unnecessary complexity across the value stream
• Sweep – Identify Services– Derive patterns, models to help with solution
• Standardize – Standard Service Definition – Define, declare standard services– Register them, apply governance
• Self-Discipline – SOA Leaning Curve– Cultural/knowledge transfer– Indoctrinate people (change the mind set)
SOA+ is consistent with 5S(Foundation for Lean)
Just-In-Time Binding Example
MES 1
UDDI Service
AdapterService
AdapterService
1. Services are indexed in UDDI
2. Create Order step retrieves binding information from UDDI
3. Create Order step uses appropriate Service to complete business process
ReceiveDemandTrigger
GetPlanning
Data
CreateOrder
Enterprise Service Bus
MES 2
Discussion Agenda
• Business issues driving change • Architecture and standards• Case Studies:
– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron
Refining: people & work processes
SOA Opportunity?
we need a software
framework that helps
improve the performance
of all personnel across all
Chevron refineries
must do for production management…
what SAP does for business &
what Yokogawa does for operations
Current
reliability
maintenance
control Supply & distribution
accounting
planning
trading
management
lab
good enough in the past
marketing
A New Architecture
Required Foundation
3636
12
The Approach
lead the industry, drive COTS
standards… liberate us…help them deliver what we need
push hard for services maturitythat exceeds current offerings