© 2015 IBM Corporation

Integration of Manufacturing using IBM Integration Bus

Session 1491

Tim Kimber

Technical Lead, IIB Industry Packs

Agenda

• The Manufacturing Industry

• Standards

• Technologies

• Products

• IBM Integration Bus Manufacturing Pack

• Factory automation

• Analytics

• Internet of Things

2

The Manufacturing Industry

Business 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

$

4

ISA 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 / 1

Process Control

Level 2

Supervisory Controls

Level 3

Operations Management

Level 4

Business Logistics

Level 5

Inter-Company

OPC DA / HDA

OPC UA

ISA-95/

B2MML

RosettaNet

OAGISMIMOSA

5

“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

6

7

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 products

The 1st specification, released in 1996 was for OPC Data Access

The 2nd specification, released in 1998 was for OPC Historical Data Access

The 3rd specification, released in 1999 was for OPC Alarms & Events

Most 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

OPC

Server 1

OPC

Server 2

OPC

Server 3

App A App B

The OPC Foundation

8

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 2009

Original 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

nt

Req

ue

sts

Se

rve

r

Res

po

nse

s

No

tifi

ca

tio

ns

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

9

OPC Unified Architecture

Node

Node

Node

Node

NodeNode

Node

NodeNode

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

10

OPC 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 Server

Vendor A

OPC Server

Vendor B

OPC Server

Vendor C

Item 2: Value, Quality, Timestamp

Item 3: Value, Quality, Timestamp

Item 1: 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, Honeywell

Vendor 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 Logic

COM interface

Application Logic

COM interface

COM interface

OPC Data

Proprietary Driver

MICROSOFT COM

Serial

11

OPC 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 Client

COM / DCOM

OPC DA Server OPC DA Server

Vendor SpecificVendor Specific

12

OSIsoft PI Server

Founded in 1980, HQ San Leandro California

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

Approximately $270million revenue, 50% North America

OSIsoft

PI 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.

13

Manufacturing - 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 viable

Market 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

14

Manufacturing Packfor

IBM Integration Bus

Manufacturing 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

16

Manufacturing Landscape

ODBC

JDBC

SQL

IBM Integration Bus in a Manufacturing context

Web Services

SOAP XML

Portal

Web Apps (internal)

IDOC, BAPI

Proprietary XML

Corporate Applications

ERP, Production Scheduling

Dynamics

Oracle

SAP

Web Services

HTTP, JMS

File, SQL

Web Services

SOAP, XML

Analytics

Manufacturing

Execution Systems

Decision Management

Product Quality

Management

Web Services

HTTP / JSON

Plant Staff

Mobile Applications

Supply Chain Management

Remote Telemetry Unit

SCADA

Web Services

IDOC, BAPI

SQL

MQTT

Remote Site

(satellite link)OPC Classic Server

(including Historian)

OPC DA

OPC HDA

OPC AE

OPC UA

Asset Management

OPC

B2MML

Web Services

OPC UA Server

(including Historian)

Web Services

Proprietary

interfaces

17

IBM 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:

Connectors

Data DefinitionsIntegration 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

18

Manufacturing Pack High Level Architecture

19

What does the Manufacturing Pack provide?

20

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)

20

21

Manufacturing Pack OPC Classic Nodes

Output from the DA Read Node (TagData.xsd) can drive the DA Write Node

21

22

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

22

23

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

23

24

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

24

Manufacturing Pack example Flow and Output

25

Manufacturing Pack Factory Pattern

Use the Factory Pattern to expose your sensors

Produces IIB artifacts in a few clicks

26

Manufacturing Pack Web UI

27

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 Confidential29

Internet of Things

Internet 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

31

Sense and ControlVisualise and Respond

Intelligence

and Analytics

Traditional

Backend Systems Big Data

Sensor Area

NetworkHome Area Network

Personal Area Network

Vehicle Area Network

Edge Gateway

The Realm of the IoT

Connectivity

Things

Mobile

Cloud

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MQTT and Remote Data Sources

Distance = > 250 km

Flow ControlPressureTemperatureOil Storage

Low-power, low-bandwidth / PLCs and RTUs

Upstream Center of

Operation and Control

Head officeIT Corporate Infrastructure

WAN

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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

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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 exception

Network cost reduced

Lower CPU utilization

Broken out of the SCADA prison – data accessible to other applications

Billing customers immediately after delivery

Message Broker

pub sub

transformation

Enterprise MessagingMQTT

20 Field

Devices to 1

Concentrator

Creating an Open SCADA Pipeline

35

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