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DESCRIPTION
The author has created a complete virtual model of a batch lot manufacturing factory using the IBM's modeling tool Rational System Architect. This presentation shows some of the improvements that the CORSO's Archimate plug-in brings to the traditional Enterprise Architecture environment.
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Factory Control System
A demonstration of the ArchimateSystem Architect Plugin utilization for
Enterprise Modeling
Foreword
It is assumed that the reader is familiar with the manufacturing environment, the concept of Enterprise Architecture, the concept of Business Process, and the use of Enterprise Architecture tools such as IBM Rational System Architect that has been used – in conjuction with the Archimate plug-in – to model thisdemonstration. Every figure in this presentation hasbeen created using one of the several diagrammingnotations provided by System Architect, notpowerpoint.
CONCEPTUAL LAYER
The 4Ms of Manufacturing
4 Ms
Manufacturing
Information FlowIntegration
Material FlowOptimization
.Methods.Material
.Machinery.Manpower
uses
usesuses
uses
supports
supports
The Factory Management Concept
Possible StatesLeve l What isMonitored
Piece
Processing
Running
Machine Step
Processing
Running
IdleLoadingIdle
Setting-upQueued
MovingWaitingQueued
StoredCompleteIn-WorkHeld
DeliveredBeing MadeOrdered
Routing Step
Part / Lot
Product
Work Center
Job Shop
Production
Machine
Factory
monitors
monitors
monitors
monitors
monitors
makes
makes
makes
makes
Product Aggregation
ManufacturingEngineering
ManufacturingUnit
Work CenterJob ShopFactory
Part PieceProcessing
Routing
Assembly
Routing Step Process Plan
Product
createscreates
monitors
performs
makes
monitorsperforms
makes
performs
makesmonitors
Business Collaboration
Job
Part Processing
Mfg. Unit
ManufacturingUnit
MachineOperato
r
Factory Level of Control
RawMaterial
ProductRequirementsfrom Planning
Parts / LotsRequirements
(Parts/Lots/RoutingStep Execution)
Work Orders to JobShops
Feedback fromJob Shops
CompletedProducts
Factory
Factory Locations Map
Factory Locations
Suppliers
(Cold)
GoodsWarehouse
Job Shop CJob Shop B
Customers
(Cold)
ProductsWarehouse
Job Shop A
AssemblyJob Shop
Job Shop Level of Control
Completed Detailed Components
(Parts/Lots/Routing Step Execution)
Work Orders toWork
Center
Raw Material Detail
Feedback fromWork
Centers
(Parts/Lots/Routing Step Execution)
WorkOrders
fromFactory
RoutingSteps
Job Shop
Job Shop Location Map
Job Shop Work Centers
Job Shop Services
Work Centers Control Office
ServicesControl Office
Work Center 1 Work Center 2
Stores
Work Center 3
InspectionDepartment
TransportationDepartment
MaintenanceDepartment
ToolCrib
Work Center Level of Control
(Job/Process Step Execution)
Work Orders toMachine
Feedback fromMachine
(Parts/Lots/Routing Step Execution)
Work Ordersfrom Job
Shop
ProcessingSteps
Work Center
Next Work CenterLast Work Center
Work Center Location Map
Work Center Locations
Work CenterBuffer
Machine 1 Machine 2Machine 3
Conveyor
Manufacturing Unit Level
Work Ordersfrom
Work Center
ProcessingInstructions
ManufacturingUnit
Work Center Buffer
(Pickup)
Work Center Buffer
(Storage)
Semi-finished / Finished PartsRaw-material / Semi-finished Parts
Functional Organization
Transportations
ProductionManager
ManufacturingEngineering
Manufacturing ManufacturingCosts Control
Maintenance
Inspections
WorkCenter
Operations
Mfg UnitOperations
Machine
ProductionPlanning& Control
Job ShopServices
Factory
ProductionPlanning
ProductionControl
ToolCrib
Job ShopStores
WorkCenter
AssemblyShop Floor
Job Shop
Operator
Work Order Flow
Work Order
Maintenance
Control
Inspection
ControlTransport
Control
Production
Control
Stores
Control
Tool Crib
Control
Machine
Control
Buffer
Control
Work
Center
Control
Job Shop
Control
Factory
Control
translates product
reqm't
into part reqm't and
issues WO to job shop
splits factory WO
into
workcenter WO for
specific part reqm't
translates jobshop WO
into jobs to be
assigned
to specific machines
issues to factory
with
product reqm't
Process Plan Flow
Process Plan
Maintenance
Control
Inspection
ControlTransport
Control
Production
ControlFactory
Control
Job Shop
Control
Work
Center
Control
Buffer
ControlMachine
Control
Tool Crib
ControlStores
Control
deviations from PP may occur during jobexecution.
they must be reported back for PP adjustment
despatches the PP toworkcenter accordingto operations routing
selects the PP needed bythe work orders and make
them available to jobshop
recives PP from mfg.engineering and
makesthem iavailable to
factory control
despatches PP steps tomachines according to
the assigned jobs
Routing Flow
Routing
Maintenance
Control
Inspection
ControlTransport
Control
Production
Control
Stores
Control
Tool Crib
Control
Machine
Control
Buffer
Control
Work
Center
Control
Job Shop
Control
Factory
Control
deviations from routings may be neededto cope with manufacturing constraintsthey must be reported back for routingadjustment
assigns routing steps tothe workcenters
assigns routing steps tothe jobshops
defines the sequence ofoperation to be executed
to produce a product
Service Request Flow
Service Request
Maintenance
Control
Inspection
ControlTransport
Control
Production
ControlFactory
Control
Job Shop
Control
Work
Center
Control
Buffer
ControlMachine
Control
Tool Crib
ControlStores
Control
Inspection
Request
Tool Crib
RequestTransport
Request
Maintenance
RequestStores Request
fulfills the request
issues a request toworkcenter control
fulfills the requestfulfills the request
issues a request toworkcenter control
dispatches the requests frommachine and buffer to
jobshop
dispatches the request tothe relevant service
fulfills the request fulfills the request
Material Flow
Material
Maintenance
ControlInspection
Control
Transport
Control
Production
Control
ConsumableLot Part Raw Material
Stores
ControlTool Crib
Control
Machine
Control
Buffer
Control
Work
Center
Control
Job Shop
Control
Factory
Control
Tool Flow
Tool
Maintenance
Control
Inspection
ControlTransport
Control
Production
ControlFactory
Control
Job Shop
Control
Work
Center
Control
Buffer
ControlMachine
Control
Tool Crib
ControlStores
Control
Equipment Flow
Equipment
Maintenance
Control
Inspection
ControlTransport
Control
Production
Control
Stores
Control
Tool Crib
Control
Machine
Control
Buffer
Control
Work
Center
Control
Job Shop
Control
Factory
Control
BUSINESS LAYER
An Enterprise Architecture is decomposed into three layers:
• Business Layer
• Application Layer
• Infrastructure Layer
Shop Floor Process DiagramShop Floor
Work Center
Machine
Job Shop
ProductionControl
Factory
Product
Part / Lot
Machine Step
Routing Step
Factory Process Diagram
OrderExecution
Des ign &SimulateRoutings
Update JobShops Load
Plan
Issue JobShops Orders
IssueOutsourc ing
Order
UpdateEmpirical Data
AnalyzePerformance
Monitor OrdersRate of Flow
Design Lots &Routings
Monitor JobShops
Requests
Del iverProducts
Make FactoryDec is ions
Request MPSChange
Work OrderRate of Flow
Job ShopsLoad Plan
Job ShopPerformance
FactoryInformation
FactoryEmpirical Data
Factory RoutingJob ShopCapac ity
Make or BuyData
Process Plan
Job ShopCapac ity
Work Orders
MPS
Batch Lot
Bill of Material
ProductProduct Status OrderExecuted
Production Order
MPS
Change
Outsourc ing
Upon Order
Completion
Job Shops
Feedback
Job Shop
Overload
Job Shop
Overload
Job Shop Service Diagram
Job Shop
Job ShopServices
(input)
Raw Material Detail
(output)
Completed DetailedComponents
(Parts/Lots/Routing Step Execution)
Work Orders fromFactory
Feedback from WorkCenters
(Parts/Lots/Routing Step Execution)
Work Orders to WorkCenter
Routing Steps
Job Shop Services
Job ShopServices
MaintenanceInspection TransportStores
InspectionProcess
Tool Crib
MaintenanceProcess
StoresProcess
TransportProcess
Tool CribProcess
Inspection Process Diagram
Inspection
Rescheduling
Inspection
Completed
Inspections
PlanningRandom
Patterns
Generation
Inspection
Results
Reporting
In Process
Inspection
Inspection
Sequences
Planning
Inspection
Exception
Reporting
Allocatie
ResourcesImpact Analysis Parts/Lot
Receiving
Inspection
Execution
Lot Releasing Equipment
ReleasingInspector
Engagement
Inspection Tasks
Equipment Status
Part Status
Lot Statistics
Inspection
Exception
Inspection
Resource
Allocation
Inspection
Impact
Inspections Plan Random
Pattern
Upon InspectionRequest
Lot Inspected
Exception
APPLICATION LAYER
An Enterprise Architecture is decomposed into three layers:
• Business Layer
• Application Layer
• Infrastructure Layer
Inter-layer Relations
Report InvalidInspection
Item
ReportInspected
Part Status
ReportInspection In-
process
RecordEquipmentAss ignment
ReportReady
Machine
DisplayInspection
Plan
Report Itemsto be Moved
Record LotsReady
ReportReady
Equipment
EquipmentReleas ing
LotReleas ing
InspectionExecution
Parts /LotReceiving
AllocatieResources
InspectionExceptionReporting
In ProcessInspection
InspectionsPlanning
Application Service Realization
Log-off
Inspector
Record
Special
Inspection
Charge
Record Lots
Ready
Report Items
to be Moved
Display
Inspection
Plan
Report Ready
Machine
Record
Equipment
Assignment
Report
Inspection In-
process
Report
Inspected
Part Status
Report Invalid
Inspection
Item
Report Ready
Equipment
Log-on
Inspector
Inspection
Control
Inspection
Control
Component
Inspection Control Application Service
Inspection
Process
Log-off
Inspector
Record
Special
Inspection
Charge
Record Lots
Ready
Report Items
to be Moved
Display
Inspection
Plan
Report Ready
Machine
Record
Equipment
Assignment
Report
Inspection in-
Process
Report
Inspected
Part Status
Report Invalid
Inspection
Item
Report Ready
Equipment
Log-on
Inspector
Inspection
Control
Shop Floor Application Services
Shop FloorControl
MaintenanceControl
InspectionControl
Job ShopServices
TransportControl
Production
Control
JobShop
Control
WorkCenterControl
BufferControl
MachineControl
JobControl
FactoryControl
WorkCenter
StoresControl
ToolCrib
Control
FactoryControl
Application
Job ShopControl
Application
InspectionControl
Component
MaintenanceControl
Component
Stores ControlComponent
TransportControl
Component
Tool CribControl
Component
Job ControlComponent
MachineControl
Component
Work CenterControl
Component
Buffer ControlComponent
Business and Data Objects
Equipment StatusInspection
Exception
Lot StatisticsInspection TaskPart StatusResources
Allocation
Random
Selection
Patterns
Inspection Plan
Inspection
Exception
Lot StatisticsPart Status Equipment StatusInspection TasksInspection
Resource
Allocation
Inspections Plan Random Pattern
Inspection Data Objects
Inspection Plan
Inspection Order
Inspection Job
Resources
Inspection
Request
Inspection
Empirical Data
Inspection Trend
Data
Inspection Store
Inspection
Dynamic
Inspection Data
Inspection
Shared Data
Entity Relation Diagram
Inspection_Empirical_DataNon-Key Attributes
DelaysResources_UtilizationResponse_TimeEquipment_UsageQuality_Standards
Inspection
Primary Key
Identification[PK1]
Inspection_JobPrimary Key
Identification [PK1]Non-Key Attributes
StatusCompletion_DateDurationPerformance
Inspection_OrderPrimary Key
Identification [PK1]Non-Key Attributes
Resources
Inspection_Trend_DataNon-Key Attributes
Order_FrequencyManpower_PerformanceQuality_Trend
Inspection_ExeptionNon-Key Attributes
"What Plan"Type
Inspection_PlanPrimary Key
Identification [PK1]Non-Key Attributes
Random_PatternsStart_DateEnd_Date
Inspection_RequestPrimary Key
Identification [PK1]Non-Key Attributes
RequestorStatusLot
Inspection_StoreNon-Key Attributes
SoreEquipment
ResourcePrimary Key
Type [PK1]
Inspection_TaskPrimary Key
Identification [PK1]Non-Key Attributes
Sequence
monitors
fulfills
requires /uses
issues
executes
generates
receives
creates /updates composed of
INFRASTRUCTURE LAYER
Inter-layer Relations
Work CenterServer
Work CenterControl
Component
MaintenanceControl
Component
MaintenanceServer
StoresServer
TransportServer
FactoryServer
Job ShopServer
Job ShopControl
Application
FactoryControl
Application
InspectionControl
Component
StoresControl
Component
TransportControl
Component
Tool CribControl
Component
Job ControlComponent
MachineControl
Component
BufferControl
Component
InspectionServer
Tool CribServer
Shop Floor Control Network
LAN
Work CenterIntranet
Work CenterServer
Job ShopIntranet
Work CenterPC
FactoryIntranet
FactoryPC
MaintenancePC
Job ShopPC
MaintenanceServer
MacjineController
Inspection PC
ProductionHost
InspectionServer
FactoryServer
TransportPC
Tool CribPC
StoresServer
TransportServer
Tool CribServer
Job ShopServer
StoresPC
MaintenanceHub
Inspection Hub
FactoryHub
Job ShopHub
Tool CribHub
Stores Hub
TransportHub
MachineHub
WorkCenter Hub
Infrastructure Services
Production
Supplier
Production Host
Unix Server Farm
Database Service Fi le Service Network Service
Intranet
Admin Server
Fi le Server
MessageQueuing
Mfg EngineeringServer
DBMS
PlanningServer
CICS
Supplier LAN
LAN Firewall
Supplier Firewall