IIB Manufacturing Pack v1001

IIB Manufacturing Pack 1.0.0.1 Overview

IBM Integration Bus Manufacturing Pack

Dom Storey <[email protected]>

mailto:[email protected]

mailto:[email protected]


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• THE INFORMATION CONTAINED IN THIS PRESENTATION IS PROVIDED FOR INFORMATIONAL PURPOSES ONLY.

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Important Disclaimer


Background to Manufacturing Integration Standards Technologies Products

IBM Integration Bus Manufacturing Pack

Internet of Things

Agenda

IIB Manufacturing Pack 1.0.0.1 OverviewBusiness Imperatives in Manufacturing

The Manufacturing world is moving from Mass Automation to Mass Customisation

The importance of capturing the “green dollar” – climate and eco-sensitive consumers

Demands for increased resource efficiency– Scheduling of production processes for optimal use of resources– Production Performance Analysis. – Equipment effectiveness and predictive maintenance.– Increased competition means manufacturers need to become increasingly dynamic – highly

responsive and re-configurable production facilities– Efficient despatch of production orders

Impact of BRIC and MINT economies and emergent middle class

Globalisation of supply chains, global competition with lower labour costs

$

IIB Manufacturing Pack 1.0.0.1 OverviewISA 95 Purdue Model Defines 4 separate Levels in industrial companies

Provides a simplified version of the Purdue Reference Model for CIM (Computer Integrated Manufacturing)

Also builds upon the MESA (Manufacturing Execution Systems Association) model for activities in the manufacturing control domain

Level 0 / 1Process Control

Level 2Supervisory Controls

Level 3Operations Management

Level 4Business Logistics

Level 5Inter-Company

OPC DA / HDA

OPC UA

ISA-95/B2MML

RosettaNet

OAGISMIMOSA


“SMLC supports the manufacturing industry through pursuing a comprehensive technology that no one company can undertake. Process control and automation systems implemented in piecemeal fashion will continue to limit innovation and capability. SMLC will build the business, interoperability and technology models, demonstrations, infrastructure, and project teams across multiple industry segments.”

Industrie 4.0 Industrie 4.0 is a German government strategy for promoting the computerization of

traditional industries such as manufacturing.

The 4.0 is refers to a heralded fourth great industrial revolution– Industrial Revolution 1 – mechanisation of production using water and steam power (coal!)– Industrial Revolution 2 – Mass production using electricity– Industrial Revolution 3 – The digital revolution (electronics and IT)– Industrial Revolution 4 – Machine To Machine communication, SOA loose coupling

Industrie 4.0 is aimed at producing “Smarter Factories” which:– Are more adaptable e.g. logistics processes which can automatically react to unexpected changes

in production levels– Are more easily configurable and connected to back-end enterprise functions– Use resources more efficiently e.g. machines that predict failures, trigger maintenance processes

autonomously

SMLC is a non-profit organization whose membership is available to industry, university, government laboratory, independent consultant and organization / consortia.

SMLCSmart Manufacturing Leadership Coalition


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PLC (Programmable Logic controllers) Talk to sensors and actuators

More actuators and sensors being built with in built Industrie 4.0 capability Integrated OPC Servers

Some Industrie 4.0 enabled devices


The OPC Foundation is a non-profit organization that maintains specifications on behalf of the industry.Total OPC market has 2,500+ vendors, providing 15,000+ OPC enabled products.OPC Foundation product catalog provides 1,500+ OPC enabled productsThe 1st specification, released in 1996 was for OPC Data AccessThe 2nd specification, released in 1998 was for OPC Historical Data AccessThe 3rd specification, released in 1999 was for OPC Alarms & EventsMost universally accepted standard for data exchange between:

SCADA and HMI Systems PC-based control systems Manufacturing Execution Systems

Quick adoption of the original OPC Data Access specification was driven by: Windows Component Object Model (COM) and Distributed Component Object Model (DCOM)

Europe(43%)North

America(39%)

Asia(13%)

Others (5%)

App A App B

Server 1 Server 2 Server 3

OPC OPC

OPCServer 1

OPCServer 2

OPCServer 3

App A App B

The OPC Foundation


The purpose of the OPC Unified Architecture was to enable a platform independent interoperability standard for moving data between the factory floor and the enterprise.Contributions from over 30 companies over 5 years. Specification first published in 2009Original premise built on the existing OPC DA COM / DCOM based specifications BUT improved some of its flaws:

Platform dependence on Microsoft Insufficient data models Inadequate security

No reinvention! Standard builds upon other existing standards

OPC UA Server

OPC UA Client

Clie

ntR

eque

sts

Serv

erR

espo

nses

Not

ifica

tions

Most common services offered by an OPC UA Server: Discovery – Servers provide a Discovery Endpoint which can be

accessed directly or through a discovery server. Profile Support – So client devices can decide if the server can

support their needs – eg XML / Binary encoding and Security Address Space – Read properties of the available nodes, and

read and write attributes of the variable type nodes. Notification / Subscription – A client can define a set of nodes

which the server monitors for a specified condition(s) which triggers a notification

+ +

OPC Unified Architecture

IIB Manufacturing Pack 1.0.0.1 OverviewOPC Unified Architecture

Node

Node

Node

Node

NodeNode

Node

Node Node

View

OPC UA AddressSpace

Monitored Item

Subscription

OPC UA Server

OPC UA Server API

OPC UACommunication Stack

Request Response Subscribe Notify

From OPC UA

Client

To OPC UA

Client

From OPC UA

Client

To OPC UA

Client

IIB Manufacturing Pack 1.0.0.1 OverviewOPC Data Access OPC DA, or OPC Classic as it is sometimes known, was born in the 1990s – system

integrators in the manufacturing industry were trying to incorporate the PC into factory floor applications using serial port connections.

Any application using a serial device was a candidate for a PC to replace a PLC, but there was heavy dependence on writing drivers for the serial devices!

Mission: create a way for applications to get at data inside an automation device without having to know anything about how the device works

OPC Client

OPC ServerVendor A

OPC ServerVendor B

OPC ServerVendor C

Item 2: Value, Quality, Timestamp



Group (public | local)

Device

The OPC Foundation provided a solution by combining Windows COM with an API for device protocols.Vendor explosion providing OPC Servers

• OSIsoft, Matrikon, Kepware, HoneywellVendor code determines the devices and data which the server can access, details for how it does this, and naming conventions for the OPC resources

Application LogicCOM interface

Application LogicCOM interface

COM interface

OPC DataProprietary Driver

MICROSOFT COM

Serial

IIB Manufacturing Pack 1.0.0.1 OverviewOPC Classic versus OPC UA

DA

OPC UA Base

Vendor Specific Extensions

AC HA Prog

Specifications of Information Modelsof other organizations

Data Transport

Security

Information Modelling

OPC Overview

OPC Security OPC Common

Alarms & EventsHistorical DAData Access

PLC

Alarm Management Trend Display

COM / DCOM

OPC HDA Client

OPC HDA ServerOPC A&E Server

OPC A&E Client

DCS

OPC DA ClientCOM / DCOM

OPC DA Server OPC DA Server

Vendor SpecificVendor Specific

IIB Manufacturing Pack 1.0.0.1 OverviewOSIsoft PI Server Founded in 1980, HQ San Leandro California

– 1000+ professionals, 15,000+ customer installations across 110+ countries

Approximately $270million revenue, 50% North America

OSIsoftPI Server

PI Server“interfaces”

“outerfaces”PI Server has developed 400+ interfaces designed to gather data from SCADA sources, convert to a PI readable format and then send it to the PI Server to be stored. Example interfaces are OPC, Modbus and PLCs.Typically PI Server runs on a separate computer from PI Interfaces and PI Client Applications. A PI Server “Collective” describes an HA grouping of PI Servers which can be considered as a single logical entity.

Elements are the building blocks of a PI System. Structural

elements can be arranged into a hierarchy, to represent a set of organized objects. Equipment

List, Pumps, Tanks, Flow Meters Heat Exchangers and Reactors

are all structural elements.

IIB Manufacturing Pack 1.0.0.1 OverviewManufacturing - Business Problems and IT Solutions

Rig

Mine

Factoryπ r2 h

IIB

Social is driving up expectations of real-time availability, data accuracy and types of information available across Enterprise and Supply Chain

Security through physical system isolation is no longer viableMarket drive to exploit advances in IT Security, distributed and virtualised IT solutions

Production locations are typically isolated and heavily silo-ed from IT Enterprise. Highly heterogeneous systems environments; no two locations the same

Need to make detailed operational information available to an ever increasing range of consuming applications and users without compromising production efficiency

IIB Manufacturing Pack 1.0.0.1 OverviewManufacturing and IBM Integration Bus IIB Manufacturing Pack

– Released 2Q 2014– Fix Pack 1 4Q 2014

Plant Connectivity De Facto Standards– Connectors and patterns that support current OPC industry standards for

integration of plant and machinery data and events, including a small number of vendor-specific implementations

Plant Connectivity Emerging Standards– Support for emerging OPC Unified Architecture standards to allow broader

integration to the enterprise Enterprise Connectivity

– Integrations and connectors, including MQ Telemetry Transport (MQTT), which facilitate the transmission of data from remote locations

– Web-based interface to provide operational views of data published from plant and machinery

IIB Manufacturing Pack 1.0.0.1 OverviewManufacturing Landscape

ODBCJDBCSQL

IBM Integration Bus in a Manufacturing context

Web ServicesSOAP XML

PortalWeb Apps (internal)

IDOC, BAPIProprietary XML

Corporate ApplicationsERP, Production Scheduling

DynamicsOracle

SAP

Web ServicesHTTP, JMSFile, SQL

Web ServicesSOAP, XML

Analytics

ManufacturingExecution Systems

Decision Management

Product QualityManagement

Web ServicesHTTP / JSON

Plant StaffMobile Applications

Supply Chain Management

Remote Telemetry Unit

SCADA

Web ServicesIDOC, BAPI

SQL

MQTT

Remote Site (satellite link)

OPC Classic Server(including Historian)

OPC DAOPC HDAOPC AE

OPC UA

Asset Management

OPCB2MML

Web Services

OPC UA Server(including Historian)

Web ServicesProprietaryinterfaces

IIB Manufacturing Pack 1.0.0.1 OverviewIBM Integration Bus Industry Packs

Each pack is a fully supported software product, independently delivered from IBM Integration Bus

The purpose of an IIB Industry Pack is to provide industry-specific development accelerators which solve common industry integration problems

Help users to deploy working integration solutions in literally a few clicks of the mouse. IIB Industry Pack content is structured around three delivery pillars:

ConnectorsData Definitions

Integration Patterns Monitoring

Association for Retail Technology Standards

Open Applications Group

Data Format Description Language

Open Grid Forum

Health Level 7

Digital Imaging and Communication in Medicine

IIB Manufacturing Pack 1.0.0.1 OverviewManufacturing Pack High Level Architecture

IIB Manufacturing Pack 1.0.0.1 OverviewWhat does the Manufacturing Pack provide?

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Contains several moving parts– OPC UA Read Node/ OPC UA Input Node– OPC Classic Read/ OPC Classic Write– PI Read Node/ PI Input Node– MQTT Nodes– Factory Pattern– Web UI

• Operational Monitoring• Manufacturing Integration Monitoring

– Ability to use B2MML schemas (imported from http://www.mesa.org/en/B2MML.asp)


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Manufacturing Pack OPC Classic Nodes Output from the DA Read Node (TagData.xsd) can drive the DA Write Node

IBM Confidential


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Manufacturing Pack OPC UA Nodes Can dynamically connect to OPC UA sever to retrieve valid tags at design time

Used to configure the OPC UA Read and OPC UA Input nodes Can connect securely with SSL 'opc.tcp' style connection only


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Manufacturing Pack PI Nodes Connect to your PI Server to retrieve series of PI Point tags

PI Read Node (PI SDK) and PI Input Node (PI AF SDK) PI Input node allows wildcards


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Manufacturing Pack Nodes Commonality Output of the Manufacturing nodes in TagData.xsd format

Common for all Manufacturing nodes Schema shipped in pattern: enables validation, with null support and mapping

All midflow manufacturing nodes now have 'invalid tags' terminal Decide how to handle tags which cannot be found on your server

IIB Manufacturing Pack 1.0.0.1 OverviewManufacturing Pack example Flow and Output

IIB Manufacturing Pack 1.0.0.1 OverviewManufacturing Pack Factory Pattern

Use the Factory Pattern to expose your sensors

Produces IIB artifacts in a few clicks

IIB Manufacturing Pack 1.0.0.1 OverviewManufacturing Pack Web UI

IIB Manufacturing Pack 1.0.0.1 OverviewB2MML to SAP


Future Roadmap (No priority order)

Integration Bus Nodes

– OPC Classic HDA

– OPC Classic AE

– OPC UA HDA

– OPC UA Write

– PI HDA

– PI Write

– S7 Siemens

IBM Confidential

IIB Manufacturing Pack 1.0.0.1 OverviewInternet Of Things Forecast2020 View

Source: IDC, December 2013

212B Installed Things

30B autonomously connected things

Public Sector, Distribution & Services, Manufacturing & Resources, and Consumers Lead Segment Growth Rates

Approximately 3 Million Peta Bytes Of Embedded Systems Data (Excludes Streaming, Surveillance Type Data

$8.9Trillion Of Business Value


Sense and ControlSense and ControlVisualise and RespondVisualise and Respond

Intelligenceand Analytics

TraditionalBackend Systems Big Data

Sens

e

Data / Alert

Resp

ond Control

Sensor Area Network

Home Area NetworkPersonal Area NetworkVehicle Area Network

Sensor Area Network

Home Area NetworkPersonal Area NetworkVehicle Area Network

Edge Gateway

The Realm of the IoT

Connectivity

Things

Mobile

Cloud

IIB Manufacturing Pack 1.0.0.1 OverviewMQTT and Remote Data Sources

Distance = > 250 km

Flow ControlPressureTemperature Oil Storage

Low-power, low-bandwidth / PLCs and RTUs

Upstream Center of Operation and Control

Head officeIT Corporate Infrastructure

WAN


Central Systems

Monitoring - temp, pressure... Control - valves…

4000 devices integrated, need to add 8000 more BUT:•Satellite network saturated due to polling of device•VALMET system CPU at 100%•Other applications needed access to data ("SCADA prison")

Proprietary polling protocol

Billing

Maintenance

SCADA

low-bandwidth,expensive comms

Pipeline: integration challenges


Central Systems

Billing

Maintenance

SCADA

low-bandwidth,expensive comms

Scalability for whole pipeline! Network traffic much lower - events pushed to/from devices and report by exceptionNetwork cost reducedLower CPU utilizationBroken out of the SCADA prison – data accessible to other applications

Billing customers immediately after delivery

Message Brokerpub sub

transformation

Enterprise MessagingMQTT

20 Field Devices to 1 Concentrator

Creating an Open SCADA Pipeline

Software

IIB Manufacturing Pack v1001