service description - istos · planning algorithm–based on issop optimisa-tion technology, +...

ISTOS.COM

DMG MORI PLANNING Service Description

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1 General description of services

2 Core applications

3 Add-on modules

4 Technology

5 Services


ISTOS GmbH offers an easy way to optimise produc-tion planning and control with DMG MORI PLANNING (formerly: PLANNING SOLUTIONS). The solution includes control station, production data acquisi-tion and enables the creation of interfaces for order administration/ERP. These create the foundation for optimised planning and transparent production.

Challenges in planning are always limited resources, timely feedback from the workstations and ensur-ing transparency on the shop floor and in man-agement. The solution consists in the applications PRODUCTION PLANNING, PRODUCTION FEEDBACK and PRODUCTION COCKPIT.

The PRODUCTION PLANNING application is an intel-ligent planning system, enabling automated produc-

tion planning according to defined optimisation goals and with limited resources.

PRODUCTION FEEDBACK is the application for direct feedback of production progress from the workplace. Together, they create a continuous flow of informa-tion between planning and production and allow rapid reactions and direct intervention in the situation on the shop floor.

In addition, planning and machine data can be visu-alised in the PRODUCTION COCKPIT, so that trans-parency can be guaranteed throughout the entire production process.

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The solution also benefits from the open technology, the modular microservice architecture with apps and the Integration Layer (also: Manufacturing Service Bus, MSB), which make it possible to integrate existing sys-tems such as an ERP system as required and to communicate between shop and office floor. For many customers, this is also the first crucial step towards end-to-end networking of their systems and thus towards Industry 4.0.

PRODUCTION PLANNING is installed on a local server (on-premise). The applications PRODUCTION FEEDBACK and PRODUCTION COCKPIT are designed for WEB use and will be offered as Software as a Service (SaaS) in the future.

At present, however, all DMG MORI PLANNING applications (PRODUCTION FEEDBACK and PRODUCTION COCKPIT) are installed exclusively on-premise at the customers’ sites to ensure uniform deployment.

The hardware requirements for these products depend on the individual customer requirements. These will be developed in the requirements workshop (see also point 8).

OUR PRODUCTS AT A GLANCE

Kernanwendungen

+ PRODUCTION PLANNING: Application for advanced planning and scheduling (APS) against limited resources for a dynamic planning of production orders

+ PRODUCTION FEEDBACK: Solution for production/machine data acquisition (PDA/MDA) recording and feedback on current production status and incoming orders

+ PRODUCTION COCKPIT: Dashboard to display machine- and process- specific information for a manufacturer- independent overview of production

Add-on modules

+ MASTER DATA MANAGEMENT Technology

+ INTEGRATION LAYER: Central integration level according to ISA 95 standard, specially designed for manufacturing applications, for optimized integration of individual systems into existing IT landscapes

+ ERP/MES CONNECTOR: Standardized, easy to parameterize interface for connecting a Manufacturing Execution System (MES) to any Enterprise Resource Planning (ERP) system

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2.1 PRODUCTION PLANNING

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PRODUCTION PLANNING is an APS software (Advanced Planning and Scheduling, APS). The software offers an easy introduction into optimising production planning while taking limited resources into account.

During the planning phase, PRODUCTION PLANNING takes into account the limited resources in the plant, which include the workstations, such as machines and assembly stations, as well as the employees with their diverse qualifications, tools and materials. This can also take into account the materials delivered by external suppliers.

2.1 PRODUCTION PLANNING ― Installed on-premise

TECHNICAL REQUIREMENTS*

Client hardware

+ min. 2 GHz Dual-Core CPU+ min. 2 GB freier RAM

(recommended: 4 GB)+ min. 400 MB free hard drive space

(recommended: 1 GB)+ min. full HD display (1920 x 1080 Px)

Calculation and storage requirements are dependent

on the size of the planning model and, if necessary,

may require higher values than indicated.

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Taking limited resources into account, PRODUCTION PLANNING determines the sequence of production orders according to the following optimisa-tion goals: Set-up time & costs, employee costs, pro-duction costs, lead time, work in progress, adherence to deadlines and capacity utilisation.

The complexity of PRODUCTION PLANNING is resolved in such a way that the user is able to automatically plan with limited resources and easily move orders by drag-and-drop, and all processes are recalculated automat-ically according to the defined optimisation goals.

The interactive PRODUCTION PLANNING planning tool is firmly established in the digital network between ERP (Enterprise Resource Planning) and the shop floor.


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Client software

+ MS Windows 10 or higher+ Included tools for installation:

MS Visual C++ 2012 Redistributable MS SQL Native Client 11.0 ODBC Driver MS .Net Framework 4.0 MS SQL Server Feature Pack (Shared Memory Objects, CLR Types) MS SQL Server 2014 Express LocalDB

Installation requires administrator rights.

Server

+ As per installed MS SQL server+ MS SQL server 2008 or higher

(min. Express Edition) The network license requires network sharing with

writing rights for all clients.

Network

+ 100 MBit connection (LAN or WLAN) between client and server

Target devices for this application: Desktop PCs with keyboard and mouse

*”System Resource Recommendation” (as per EULA Section C “Transfer of software”, IV Obligation to cooperate; point 3)

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For order and production optimisation, Production Planning offers customers:

+ Order optimisation through a multi-variable planning algorithm–based on ISSOP optimisa-tion technology,

+ Innovative multi-resource planning (machinery, personnel & production resources and tools),

+ Classification of leader jobs (prioritisation) in the ongoing planning,

+ Visualisation of downtimes and malfunctions,

+ Congestion management,

+ Observance of quality assurance,

+ Visualisation of planning results in the graphical control station,

+ Overall analysis of all production orders with planning information,

+ Simulative Scenario Manager.

Comprehensive reports enable you to track key

performance indicators (KPIs) and allow the

evaluation of various planning and control

parameters over longtime periods.

Reporting

Order networks

The clearly arranged control panel displays all

orders and production processes with the used

resources at a glance and provides a transparent

overview about the manufacturing networks.

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PRODUCTION FEEDBACK is a web-based software for production data acquisition (PDA).

The following core functionalities are included:

+ Display of all orders

+ Recording of actual data from production

+ Report of possible errors

PRODUCTION FEEDBACK can be used to report the status of production orders, their results with time used and number of parts produced as well as possible mal-

functions back to production planning.

2.2 PRODUCTION FEEDBACK ― Web-based


Client hardware

+ Monitor with 1920 x 1080 Px (Full HD, 16:9)

Client software

+ MS Windows 10 or higher


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2.2 PRODUCTION FEEDBACK

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This makes it possible to respond to changes quickly and flexibly, which in turn enables agile production. The aim here is to fulfil customer expectations at short notice while also taking adherence to deadlines, costs and quality assurance into account.

PRODUCTION FEEDBACK is divided into two areas. Firstly, the actual status is entered directly by the op-er-ator via a terminal, this is called production data acqui-sition (PDA). Secondly, data can be taken directly from the machine as a status, this is called machine data acquisition (MDA).

An example of this process could be: Production orders are created in an ERP system. These are transferred to a planning system for detailed planning, which plans the orders in detail and then transfers them to PRODUCTION FEEDBACK. These production orders are now available to the user at the terminal or the machine. Continuous feedback of current status can now take place during the production process. Based on this real-time feedback, the planner can adjust and update schedules directly.

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Webbrowser

+ Google Chrome 61.0 or higher

Network


Server hardware

+ Processor: 2,1 GHz; 8 CPU cores+ RAM: 32 GB+ Hard drive: 480 GB SATA SSD, Raid 5

The communication to other systems is possible

via Integration Layer. Target devices for this application: SIEMENS control with CELOS V5, Desktop PCs with keyboard and mouse


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PRODUCTION COCKPIT is an application that accesses data and information from a wide variety of applications to be defined in the requirements workshop and bun-dles them in an overview (hereinafter referred to as the dashboard).

The dashboard is created using a Dashboard Designer that allows you to display different information in the form of widgets and configure them in terms of size, position and widget-specific options. Pre-defined wid-gets are provided via the PRODUCTION COCKPIT.

2.3 PRODUCTION COCKPIT ― Web-based


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2.3 PRODUCTION COCKPIT

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Client hardware

+ Monitor with 1920 x 1080 Px (Full HD, 16:9)

Client software

+ MS Windows 10 or higher

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Webbrowser

+ Google Chrome 61.0 or higher

Network


Server hardware

+ Processor: 2,1 GHz; 8 CPU cores+ RAM: 32 GB+ Hard drive: 480 GB SATA SSD, Raid 5

The communication to other systems is possible

via Integration Layer. Target devices for this application: Desktop PCs with keyboard and mouse

These are widgets that display data from DMG MORI PLANNING applications as well as from other DMG MORI or CELOS applications. They can be selected and, if necessary, configured in the Dashboard Designer. Furthermore, it is also possi-ble to create widgets for non-DMG MORI application widgets using individual programming and these can then be made available in the PRODUCTION COCKPIT Dashboard Designer.

PRODUCTION COCKPIT is the frame application that uses widgets from other applications (currently: PRODUCTION PLANNING and PRODUCTION FEEDBACK). Each user can compile dashboards and overviews for his specific use case. There are plans to create widgets for other applications, but these must be purchased along with the application.

PRODUCTION COCKPIT consists of the following components:

+ A configurable dashboard panel on which all dashboards are displayed. _Overview of all dashboards, _Can be configured according to individual needs.

+ A Dashboard Designer that allows you to create your own overviews/views by adding predefined widgets and the ability to customise their size and position. This allows relevant information to be mapped to an overview.


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+ Standard widgets, which can display infor-mation independently of other applications and be added to the dashboard, are used to display custom text fields or graphics.

+ DMG MORI widgets, which display the rele-vant information, e.g. Planning Gantt Chart from PRODUCTION PLANNING, in a widget, in order to add it to a dashboard and to adapt it to a certain extent. _Access information from other DMG MORI PLANNING applications as well as from other DMG MORI or CELOS applications, _Adaptability of the predefined widget accord-ing to position and size.

This application and its features offer a tool for visualisation and communication of information for the customer in a wide variety of applications and the option for individual configuration.

This service description only covers the frame application, with which it is possible to create individual dashboards with the aid of widgets. It provides standard widgets. The requirements for the individual DMG MORI widgets are not part of this product description.

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„As a production manager, I need a quick

overview of production, and within only a few

seconds, so that I can immediately react if

something is not working as planned.“

Production manager

Maintenance technician

„As a maintenance technician, I need the

information on my machines as quickly as

possible so that I can immediately analyze

which machine needs which service.“

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3.1 MASTER DATA MANAGEMENT

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3.1 MASTER DATA MANAGEMENT ― Web-based

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MASTER DATA MANAGEMENT (MDM) is the cen-tral data management for master data and offers a platform in which it will be possible to uniformly define and manage critical data from all applications using a single reference source in the future. Stan-dardisation and agreed rules for the uniform use of data provide a leading instance for master data that is relevant for all applications.


Client

+ MS Windows 10 or higher+ Google Chrome 61.0 or higher+ Monitor with 1920 x 1080 Px (Full HD, 16:9)

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The master data of the applications and modules remain stored in the MDM, even if an application should be removed. This precaution ensures the permanent and autonomous ability of the other modules to run with the stored data. MDM is the data backup that communicates with both inter-modular and external programmes by means of the Integration Layer (also: Manufacturing Service Bus, MSB)

The following modules for master data manage-ment have been implemented so far:

+ Equipment

+ Basic Information / Organisational Structure

+ Basic Employee Management

Note: MDM is an integral part of the framework applica-tion of DMG MORI PLANNING applications and is not suitable for managing own master data inde-pendently of DMG MORI PLANNING applications.

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Network

+ 100 MBit connection (LAN or WLAN) between client and server The communication to other systems is possible

via Integration Layer.

Many manufacturing companies plan on network-ing applications and machines in order to make pro-duction more efficient and flexible. This rad-ically changes the demands on the IT infrastruc-ture. Mov-ing forward, the IT infrastructure must be continually able to adapt to changing data struc-tures and new business requirements to enable permanent end-to-end communication between applications in companies and beyond and to ensure interoperability between all systems.

On the other hand, implementing different software solutions today is often very time- consuming and costly, since each solution provider works with their own data formats and a propri-etary data structure. What’s more, the interfaces of new applications and cloud services have to be extensively adapted in order to establish commu-nication among each other.

The Integration Layer (also: Manufacturing Service Bus, MSB) from ISTOS is a consistent integration layer with a standardised data structure and data description. It replaces the complicated network of end-to-end connections in the application land-scape with a communication infrastructure that is used by all connected endpoints (applications, service providers and users), allowing them to communicate with each other on the basis of the recognised data format (JSON Schema), industry standard ISA 95 and an ISTOS – specific extension.

Compared to other Enterprise Service Bus sys-tems, the special feature of the ISTOS Integration Layer is the fact that it specialises in the manu-facturing industry and therefore specifically allows scenarios where applications can be integrated in production processes and data-intensive applica-tions in production.


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DETAILS ON FUNCTIONALITIES:

- Common data formats (described by JSON Schema)- Recognised industry standards (ISA 95)- Communication protocol (MQTT)

Note: The Integration Layser cannot be purchased separately. It is used to exchange data bet-ween the individual DMG MORI PLANNING applications and cannot be used as a stand-alone product.

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4.1 Integration Layer

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The implementation effort for PRODUCTION PLANNING depends on the specific wishes and circum-stances of the customer. Expect an aver-age effort of around 20 days for planning up to 50 resources (machines and manual workstations).

Before DMG MORI PLANNING or individual prod-ucts can be introduced, an inventory of the exist-ing IT system landscape and desired requirements must be taken. One to two-day workshops are offered, depending on the scope. This inventory and requirements analysis includes comprehen-sive on-site advisory services to the customer regarding the implementation and mapping pos-sibilities of existing machines, work steps and pro-duction processes using DMG MORI PLANNING, organises the planned implementation project into the first phases of implementation and works with the customer to define the preliminary mea-sures required. The customer also receives a list of requirements, which constitutes the basis for the resulting project realisation.

A binding offer for implementing DMG MORI PLANNING can be made to the customer on the basis of the workshop.


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5.1 Requirements workshop at the customer‘s site

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5.1 Requirements workshop at the customer‘s site

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Workshop results are used to calculate the cost of developing interfaces from inventory systems, e.g. ERP/TDM/BOM to the Integration Layer (also: Manufacturing Service Bus, MSB), in the form of customised solutions depending on the complexity of the project.

The service includes:

+ Data mapping and transformation (adapters),

+ Adapters for Software-as-a-Service (SaaS) and locally installed applications.


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5.2 Developments

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5.2 Developments ― Adaptors and interfaces

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As part of implementation, we offer the following approach:

Project step 1: Project launch

Further details on introducing DMG MORI PLANNING and finetuning the work packages and mile-stones for all those involved in the project will be provided at the start of the project.

Project step 2: Interface programming

In this step, the interfaces for data exchange between the Integration Layer (also: Manufactur-ing Service Bus, MSB) of DMG MORI PLANNING and the enterprise-specific third-party systems at the customer company are programmed or adapted in line with the definitions in the detailed specification.

Project step 3: Installation and set-up of the

test position

Once the interfaces have been completed, a DMG MORI PLANNING test position is set up in the customer’s company to test their functionality.

Project step 4: Customised solutions

In this project step, customised solutions defined in the detailed specification that go beyond the standard application are implemented in DMG MORI PLANNING.

Project step 5: System validation and

initial operation

After successfully completing project step 4, the entire system is put into operation. Close cooper-ation with the customer is necessary in this phase. The customer’s obligation to cooperate is to provide the required internal resources. The test with live data provides the basis for analysing the planning results achieved. The planning quality is continu-ously improved over several iteration steps. The re-sult is a customised installation of the solu-tion that corresponds to the goals defined in the detailed specification and is adapted to the cus-tomer’s individual requirements.

Project step 6: Training

The training package includes an introduc-tion to the fundamentals of working with DMG MORI PLANNING and user training. Special attention is paid to the creation of planning scenar-ios, their interpretation, the use of control param-eters and target criteria to optimise the results of the PRODUCTION PLANNING product. Training is also provided on content for simulating scenarios, evaluation options in the control station, working with the existing analysis tools and generating the required reports.

If you have any further questions about our products, please contact your per-sonal contact or send an e-mail to: [email protected].


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5.3 Implementation & training

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5.3 Implementation & training

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ISTOS.COM

ISTOS GMBH

Intelligent solutions for the Digital FactoryThe products and solutions of DMG MORI PLANNING are developed by ISTOS, a subsidiary of the DMG MORI group. ISTOS stands for „Innovative Software Technologies for Open Solutions“.

Our goal is to establish network-based manufacturing prosesses across all machines along today’s supply and value chains, and to provide data-intensive applications for setting up consistent digital value-adding network of tomorrow.

Talk to us! For questions and offers we are at your service.

Christian Methe, Managing Director ISTOS GmbH Phone: +49 (0)151 40244566 [email protected]

ISTOS GmbH, Kaistraße 16a, 40221 Düsseldorf

PLANNINGFEEDBACKCONTROL

service description - istos · planning algorithm–based on issop optimisa-tion technology, +...

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