smart industry 2015: maclean-fogg uses iiot to gain industry advantage
TRANSCRIPT
MacLean-FoggUses IIoT to Gain Industry Advantage
Chris Misztur
Scott Masker
with Tony Paine
Agenda
• Company overview
• Industry 4.0 meaning
• Opportunities
• Change model
• Global architecture
• How to start
Company Overview
• Private enterprise• 3000 employees• 34 locations• $1bn+ sales• 100+ patents
• Electric utility• Telecommunications• Civil markets
• Fastener components • Engineered components• Engineered plastics• Linkage and suspension components
• Investments• Private equity holdings
Industry 4.0 Meaning
• Established 2010• Internal lean manufacturing training• Employee empowerment• Operator = doing + thinking• Executive backed
operational transformation
informationtechnology
• ERP implementation• Not only a support department• Value add opportunities
• Innovation• Waste elimination• Process stability
joint effort
Opportunities
• Operational unknowns• Machine efficiency• Defect rates• Machine downtimes
• Excess inventory• Quality problems• Long lead times
$$$
• Non-value added activities• Weighing product• Piece reporting• Inspection & rework
Change Model
business needs
software hardware
.
visualization of accuratereal-time information
The Way Forward
.
Change Model
assets PLC Kepware BizTalk JD Edwards
• Started at 1st process• Already had PLC• Internal counters
Kepware BizTalk JD EdwardsPLCassetsChange Model
.
Serial Devices
• Less than 50% equipment connected
• Some equipment serial connected via outdated legacy drivers and software
• Start looking at lower cost alternatives to PLCs
Kepware BizTalk JD EdwardsPLCassets
Change Model
.
Kepware BizTalk JD EdwardsPLCassets
Change Model
Kepware
• Hub for real-time machine communication
• Standardizes PLC wire protocols to OPC-UA
• Bridges shop floor and data center
IOT agents
MQTT HTTP
• publish-subscribe• lightweight• portable• topic based• Facebook
• REST API• request-response• read and write• Internet standard
BizTalk JD EdwardsPLCassets
How to get the data out?
OPC-UA
DATABASE
SPLUNK
Change Model
• Topic kepserver/0200/forming/1696
{"timestamp":1443294150155,"values":[{"id":"0200_Forming.1696.GoodPieces","v":"1389","q":true,"t":1443294140795},{"id":"0200_Forming.1696.DefectivePieces","v":"0","q":true,"t":1443294140795},{"id":"0200_Forming.1696.AssetNumber","v":"1696-1200","q":true,"t":1443294140795},{"id":"0200_Forming.1696.WorkOrderNumber","v":"92800-000","q":true,"t":1443294140795},{"id":"0200_Forming.1696.WorkOrderOperationSequence","v":"11","q":true,"t":1443294140795},{"id":"0200_Forming.1696.EmployeeNumber","v":"64500","q":true,"t":1443294140795}]}
Kepware BizTalk JD EdwardsPLCassets
• Earlier models• Topic per data point (client blocking)• Publish only changed data (chatty)
division department asset
Change Model
BizTalk JD EdwardsPLCassets KepwareChange Model
Apache ActiveMQ
Kepware
JSONkepserver/0200/forming/1696MQTT publish
JMS API subscribe
IOTGateway
kepserver.*
• process• store/forward• analyze
Change ModelBizTalk JD EdwardsPLCassets Kepware
• XML messaging platform
• Microsoft SQL backed
• Receive and send ports
• Orchestrations • XLANG/s BPEL
• Messaging language• C# expression
ü Fileü FTP (FTPS)ü HTTP(s)ü MSMQü POP3ü SFTPü SMTPü SOAPü WCFü SB-Messagingü MQSeriesü SharePointü TCP-IP Socketü Oracleü SAPü PeopleSoftü JD Edwardsü LDAPü JMSü RSSü SSHü AMQPü XMPPü Salesforceü Dynamics CRMü Googleü Twitterü Facebookü Faxü PowerShellü ZeroMQ
Change ModelBizTalk JD EdwardsPLCassets Kepware
(typical development scenario)
change modelBizTalk JD EdwardsPLCassets Kepware
kepserver.*
JSON XMLreceive pipelinereceiveport
processing orchestration BPEL
JMS
sendports
JDE REPORT PIECESCOMPLETED
SQLUPDATE ASSET OEE
JMSASSET ACTIVITY
cm
(ALTERNATIVE)
Enterprise SystemWith All Needed Modules
Change ModelBizTalk JD EdwardsPLCassets Kepware
.
Finance
Asset Management
Order Management
Reporting
Mobility
Production
Open architecture allowing for customization
Change ModelBizTalk JD EdwardsPLCassets Kepware
.
BizTalkJDECustomFunction
InteroperabilityTable
BackflushFunction
Small Data Set [WO UserQuantity ] Enterprise
Data
CompletionMessage
JDECustomFunction
BizTalk
cm
Completion OKOrErrors Reported
Global Architecture
Kepware
Kepware
factory A
factory Z
ActiveMQBizTalk
JD Edwards
data center
How to Start
• Start where you know
• “Borrow” hardware from your controls engineer
• Write some MQTT code
• Become familiar with message brokers
How to StartBizTalk JD EdwardsPLCassets Kepware
• You’re not a Microsoft shop?• My personal rapid prototyping platform
• Open source• Document store• XQuery (XML,JSON,Unstructured)• JMS API support• JAVA plug-ins• Web server• REST API
Questions?
Kepware
BizTalkJD Edwards
ActiveMQ
vendor specific
MQTT
Payload containing work-order, employee, and piece information
JMS
Call business function
Run BackflushProcess
Business function response
