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Wonderware Enterprise Integration Application By Tim Sowell

Wonderware Enterprise Integration Application

Highlights

In today’s competitive and dynamic manufacturing environment, there is a critical need to complete the manufacturing supply chain by linking the manufacturing system to business applications (e.g. SAP, Oracle Apps, JDE,). Wonderware’s Enterprise Integration is a new generation application, designed to enable the enterprise integration that is fundamental to achieving the Enterprise Manufacturing Eco System required for business/ manufacturing agility.

Wonderware's Enterprise Integration Application is an ArchestrA Application that addresses the problem of integrating your manufacturing facilities by enabling:

• Enterprise Application Integration to Manufacturing (e.g. SAP, Oracle Applications, JDE etc) and to other applications in your supply chain.

• Multi Manufacturing-site Integration between different manufacturing solutions on different sites. You may have multiple-based applications, or other manufacturing solutions that must link together to complete your manufacturing supply chain. For example, a product completed at one site needs to be consumed in another plant.

• Transactional Integration between Manufacturing and Other Supply Chain Applications of the different applications in your manufacturing environment.

• Integration with your existing messaging and middleware investments (such as Web sphere, Tibco, MQ Series etc), avoiding impact on existing infra-structure and IT strategies.

Fig 1: High Level Positioning of Wonderware’s Enterprise Integration Application


Wonderware’s Enterprise Integration Application provides the capability of operating automatically, transparently sending and receiving messages, forwarding and transforming the message content, while controlling the sequence of operations required to keep two or more applications interconnected.

By providing powerful real-time event capability and plant integration, and leveraging the highly flexible new generation plant/real-time event system from Invensys’s ArchestrA technology, combined with powerful orchestration / workflow management functionality from Microsoft’s Biztalk 2004, you get unparalleled:

• Architectural freedom • “Out of the box” integration to hundreds of applications in both the

Manufacturing automation space, and business applications • Powerful graphical configuration to enable assembly, not programming, of

Message transformation, and event detection • Configuration of Workflow transformations, and real-time event mappings, so

they can be easily established and maintained • A very flexible/robust architecture, which allows your existing business system

and manufacturing systems to work in a complimentary way, that is loosely coupled, yet extremely reliable

This ArchestrA application extends capabilities to address this transactional business integration required today.

Addressing Integration Requirements

Wonderware sees the key need to provide an integration solution that avoids the complexity of creating and maintaining priority interfaces, while still providing the following capabilities:

• Powerful multiple application workflow orchestration and transformation mapping. • Built in event handling and integration of events to the Manufacturing System • Scaleable from a small pilot to multi-site. • Ability to configure workflows in non-programmatic environments. • Security between non-trusted environments. • Robustness, guaranteed message delivery through High Availability Architectural

Options. • Ability to build standards and reusable “rules”, “transformations” and “workflows”

which can be rolled out across multiple sites in the organization. • Based on S95 standards part 1, 2 and the message structures defined in B2MML

messages; but being extendable, in being able to customize these message structures to fit your application.


• Ability to seamlessly integrate with components, while also being able to integrate with non-Wonderware automation packages and other databases.

• Support for integration standards such as SQL, ODBC, XML, and OLE

Industry Standards

Wonderware recognizes the requirement to have a successfully integrated manufacturing ecosystem. That is, the Business System and Manufacturing System, and the Manufacturing Systems themselves must have loosely coupled solutions that interact in a non-intrusive manner. Most important is the robustness in message delivery and notification of the different systems in a transparent, automatic manner. This design philosophy enables each system to perform its duty at its required rate, while interacting with other systems in a timely manner.

Following its tradition for building solutions that employ robust, market-accepted technologies and industry standards, Enterprise Integration leverages:

• ISA 95 Part 1, 2 standards for manufacturing to enterprise integration. As a voting member of the ISA S95 committee, Wonderware actively provides direction for the standard and brings this expertise to you.

• B2MML Standards • ArchestrA, which is included as the Event System • Microsoft's popular Biztalk 2004 technology • OPC for real-time connectivity to Plants. • SQL / OLE DB support DB integration.

By combining these standards and technologies with proven libraries of pre-built integration applications, you can get up and running faster and with lower risk. Library of Pre-Built Integration Templates

An option to Wonderware’s Enterprise Integration is a set of Pre-built Integration Templates. Pre-built Integration Templates provide the ideal starting point for your application. They leverage proven solutions, while still enabling you the freedom to customize them according to your application. The Enterprise Integration library of Pre-built Integration templates cover such integration scenarios as:

• Production Schedule Download from ERP (using B2MML Product Schedule message) to create and schedule work in the manufacturing environment, enabling a S95 schedule to create automatically Batches and Lots in that are ready for executing.

• The Upload of Production Performance throughout the manufacturing life of the work order, providing the ability to configure the S95 Process Segments


events relative to your manufacturing model, enabling the uploading of production parameters as required into the S95 (B2MML) Production Performance Document.

• InTrack to InTrack Integration Template enables you to link your existing InTrack manufacturing facilities together. You can ship from one InTrack system and receive into another automatically, based on plant production events.

• InBatch to InTrack and Industrial Application Server transaction integration templates allow you to have InTrack as the manufacturing model, schedule batches in InBatch, and upload results /consumables back into InTrack on batch completion, enabling inclusion in the product history.

• Condition-based monitoring integration to your Preventive Maintenance Application, providing the ability to transform Asset Condition Monitoring KPIs from a plant floor condition based monitoring system to your Preventive Maintenance System, automatically.

These Pre-built Integration Templates are under constant development, so this list will continue to grow, feedback will be provided when your application is evaluated.

Benefits of Wonderware’s Enterprise Integration Application

The significant benefits of Wonderware’s Enterprise Integration Application are:

1. Ability to traverse the different Security models in a business in a secure manner. Critical to an integration solution today is being able to inter-connect applications that exist in different (often not trusted) security domains, without compromising the security of either domain or applications. In today’s environment, a secure/well-planned business security model will have multiple firewalls that isolate the manufacturing/plant floor applications from the rest of the enterprise. Yet to run an effective Manufacturing ecosystem, these applications must pass messages. Enterprise Integration Application was designed to enable this integration in a secure environment.

2. Multiple Enterprise, Supply Chain Application integration. Enterprise Integration provides adaptors that connect to hundreds of enterprise applications such as:

• ERP System: SAP (includes classic certified Idocs Adaptor, as well a New SAP XI interface), Oracle Manufacturing, JD Edwards, Baan, I2 Technologies

• Message Interfaces: MSMQ, IBM MQ Series, Web services, XML, OLE DB, SOAP etc.

3. Scalability. You do not know what you will need tomorrow, and this applies to the integration of your enterprise. The most logical approach is to start with a pilot and then scale up. Enterprise provides the ability to scale on these key dimensions:

• Number of real-time plant connections. • Number of workflows, and transformations.


• Number of application connections being integrated.

With its flexible architecture (fig 2), WWEI provides the ability to evolve architectures to fit your IT structures and physical distribution such as:

• A pilot with one Plant connected to One Business system. • Many Plants physically distributed connected to one Business System. • Many or One Plant Systems connected to Many Business Systems.

Fig 2: Enterprise Integration High-level Architecture

Figure 2 shows the core architecture of the Wonderware Enterprise Integration Application while a latter section will discuss some possible topologies, it is important to understand the main modules of the Wonderware Enterprise Integration Application:

• Business Orchestration Module:

This module provides workflow and transformation capability with the ability to listen and interface to messaging systems and APIs. For this we will leverage Biztalk 2004 and range of adaptors available on the market. There is an interface between Business Orchestration Module and Manufacturing Module, which can pass across firewalls.


• Manufacturing Module:

This is the module that lives with the manufacturing automation system, either apart of the system, (in the case where IAS is already installed), or on top of existing automation system. Integrating to the existing system through Suite link, DDE, OPC, or SQL, standard with ArchestrA. This module will be independent of the Business Orchestration, and will be located locally and be able to survive on its own. It will include and IAS small (250 I/O) and 200 Production Events (Traceability), with a Production database in MS SQL Server, which is a S95, database schema for both “planned” and “actual” data. This will enable schedules to be downloaded from SAP and stored in this until required.

• Application Adaptors:

These are Biztalk adaptors which we will supply as part of the solution, leveraging BizTalk’s adoption in the market; we will obtain these adaptors from MS under our ISV contract, or iWAY who has hundreds of adaptors. We will charge for these as additions to the solution.

• Production Operator Display (future past Rev 2, sold as optional Extra):

This is a display that enables the user to:

1. Enter a schedule manually if the ERP system is down.

2. Display proposed orders.

3. The ability to assign Captured production events to an ERP production Order after the events have happened.

4. The ability to release locally Production Orders to manufacturing, e.g. act as a dispatcher.

This display is not a part of WWEI but will be a component designed to work with it, and add significant functionality, it is not expected until mid 2005.

4. Built-in Administration Tools. Core to both base technologies of ArchestrA and Biztalk is the fundamental ability to administer the application, and “instrument up the application” so that you determine issues in a pro-active manner. By incorporating Industrial Application Server as a powerful event system, errors can be notified as part of the Plant Alarming System, and notification can be both logged and sent via email or telephone to selected personnel. Through Wonderware’s Portal (Suite Voyager) the user is able to integrate powerful reporting and dashboard capability to bring the information to users fingertips.


5. Integrated Real-time Event Engine. ArchestrA’s Event Engine (Industrial Application Server) enables you to configure plant events, integrating with whatever plant automation systems that are installed, connecting through hundreds of interfaces and OPC. Due to ArchestrA’s distributed architecture, you are able to apply multiple distributed Event Engines local to the plants to detect events. Even though these engines can be physically distributed, they are managed as one, and integrate seamlessly with one or more Orchestration engines which can be located in another domain and location. This provides you with unparalleled flexibility and high availability options.

6. A Powerful Orchestration Environment (Fig 3). The environment enables you to configure the flow of messages traveling from one application to another application. You can create an unattended execution schedule that can be based either on time events, or directly on plant events defined in the real-time event engine, which is constantly receiving, transforming, and forwarding messages.

Figure 3 Graphical Workflow Configuration Figure 4 Messaging Mapping

7. Highly Flexible, Reusable Mapping Transformation Capability. The key to passing messages between applications is the ability to transform and map the different schemas. Through MS BizTalk’s powerful “data mapper”. See Figure 4, you can build this mapping visually and save it as a reusable transformation from one workflow and one project to another.

8. Use of ArchestrA’s Real-time Application Integration Platform of Services. By being built on ArchestrA, the system inherently benefits from the extensive services included in ArchestrA, especially those associated with alarming, event, customization and scripting, the ability to build standards when modeling the real-time manufacturing world, and the tight integration with the rest of.

9. Engineering Efficiency and Lower Solution Risk. Through the use of pre-built and tested adaptors to applications, and ArchestrA component-based application


model, Enterprise Integration is built to allow you to configure and assemble solutions that avoid programming.

10. Certified System Integrator Program: In order to make sure implementations are done correctly Wonderware has initiated a special Wonderware Enterprise Integrator Certification program for system integrators. This is designed to enable you and us to choose the best partner to implement your project, Wonderware can recommend existing certified SI’s, or Wonderware can provide Application Experts to work with your preferred SI on the initial project in order to transfer knowledge and bring them up to certification level. See program below.

11. Named Application Expert Support Built In: Due to the complex nature of the enterprise integration problem, Wonderware has included as part of the WW Enterprise Integrator Application 40 hours of specialized named support to the certified system integrator in order to make sure the application is a success. The support will provide:

Kick off project review meeting via webex.

A direct contact for Phone, Electronic Project Support, up to 40 hours.

Review of Project Architecture and approach via webex.

• Pro-active review at defined milestones of project. .

Application Architecture Reviews

Now that you have a basic understanding of the WWEI Application functionality it is worth having a look at two possible application topologies in which it could be applied. Note these are not the only possibilities but are the more common applications relative to business application integration. The first topology illustrated in Fig 5, is commonly what is found in companies where they have:

• Central Business System • Multi Manufacturing Sites physical distributed.


Bus iness Orchestration

Module LoopTFLoop

TF

S95

Manufacturing Module

InS QL InTouchManufacturing Site 1

Netweaver XI

Central Business Site

In this case the user has a central ERP which is wrapped in some middleware and they place message onto a cooperate messaging system. The idea is that we are required to listen and pick up these and process them for the plant, same on the upwards where we collect production information and place this in a message on the message system.

Option 1: Enterprise Integration Architecture

Websphere

MercatorOther I/F

Corperate Messaging S ys tem: MQ Series , MSMQ, Tibco etc


Module

LoopTFLoop

TF

S95




Module

LoopTFLoop

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S95



Figure 5 Central ERP Wrapped in a Messaging system

Many organizations as they implemented their business system e.g. SAP, Oracle have one central instance and then have wrapped this business system in some sort of middleware in order to allow the processing of incoming or outgoing messages to the multiple sites, and other business applications. Many companies have used Mercator, Websphere and now Biztalk to do this, then leveraging some sort of corporate message system e.g. Tibco, MQSeries, MS MQ, and web services to manage the delivery of these messages between different sites and applications. With SAP’s drive for implementing SAP 4.7 and the Netweaver technology, this type of application architecture will become even more common, where Netweaver provides a powerful transformation, and business flow environment for transforming incoming and out going messages to the appropriate calls within the R3 system. Especially in the manufacturing environment where companies are striving for standard messages between the different sites, using the S95 (B2MML) standards as a solid basis. Having determined a common message structure at the business end, the proposed architecture places a WWEI Application at each site, so that it can listen and collect the incoming messages, transform these to the required calls needed in that particular site. Note usually each manufacturing site will require it’s own plant transformation of the standard messages. A simplified example of functional flow for this architecture is:

• The ERP System sends say a schedule; this is transformed by the ERP Middelware (lets say Netweaver’s XI) to the S95/ B2MML Production Schedule Message and placed on the message bus.


• The messaging system delivers the message to the correct manufacturing site. • The WWEI Business Orchestration Module collects the message at the

manufacturing site, and transforms this message through workflows into the S95 Production DB. This enables a production schedule of a number of days to be stored locally; in case the SAP connection is lost manufacturing will continue. This architecture allows for customization of these workflows and mappings, as well as a manual entry system to be provided to allow schedules to be entered via a local terminal.

• The WWEI Manufacturing module will pull the scheduled orders and make the required calls to the batching/ MES system to start executing the orders. It will also monitor all production events, collecting all required data and transforming this to the S95 Production DB ready for uploading to the business system.

• On a particular process update event, or business system request the Business Orchestration module will query the S95 Production DB and build the required S95 Production Performance Message and place it on the message bus.

• The message system sends it to Business System. • The business Systems Middleware collects the message and transforms it to the

required calls in the business system. While this is simple example, it shows how the WWEI Application in this architecture compliments the Business System Middleware to provide a loose coupling, and are robust architecture where a standard business interface can be established with common messaging structures, while maintaining the uniqueness of each manufacturing site, and the existing MES/ Batch systems that run those sites. From our experience this architecture is a good scaleable, robust topology, suiting most multisite organizations. The second topology illustrated in Fig 6: illustrates a more typical application architecture applied to companies, which have not implemented a middleware/ common messaging system between the different manufacturing sites. In this case the WWEI Business Orchestration module is located local to the business system, with the appropriate adaptor to interface to the business system directly making calls, (e.g. SAP Certified Idocs Adaptor, or Oracle Manufacturing Adaptor, etc). Usually we have found that both the Business System (e.g. SAP) and the WWEI Business Orchestration Module must be in the same trusted security domain. The proposed architecture provides local WWEI Manufacturing modules local to each manufacturing site, the communication between the WWEI Business Orchestration module, and WWEI Manufacturing Module is secure leveraging web service technology. The flow is similar to example 1 but now the ERP directly calls the WWEI Business Orchestration module through the adaptor, and the data (schedule is passed). The WWEI Business Orchestration module transforms this into messages that are sent to appropriate manufacturing site, to be stored in the local S95 Production DB, ready for process similar to example 1. The same flow is also achieved on uploading messages from the manufacturing site to the ERP system.


Bus iness Orches tration

Module

Loop

TFLoop

TF

S95 Planne

d

S95 Actual

Realtime-Engine


S95 Planne

d

S95 Actual

Realtime-Engine

Manufacturing ModuleS95

Planned

S95 Actual

Realtime-Engine


InS QL InTouch InS QL InTouch InS QL InTouch

Manufacturing Site 1 Manufacturing Site 2 Manufacturing Site 3

Netweaver XI

Central Business Site

WonderwareEnterpriseIntegrator

Option 2: Enterprise Integration Architecture

Websphere

MercatorOther I/F

In this case the user has a central ERP which is wrapped in some middleware or the natural API, WWEI will provide adaptors

Figure 6 Central ERP but with no Standard Messaging.

This approach is found on companies that have only one manufacturing site, or where their business system is local to each site, effectively they are running each site, as its own business. Also companies that have business systems that have no way of wrapping them in some standard middleware. While each company needs to be looked at on a case by case basis, it is recommended that if a company has the plan to go to a central business system, with multiple physically distributed manufacturing sites they should seriously consider standard messaging approach and architecture proposed in example 1.

Comments on Mapping Between Business System and Manufacturing System

The focus of the business system is different to that of the manufacturing (MES) system, and they should be in order to be optimized to perform their required tasks within the organization. Due to this different focus a different terminology and grouping is applied and this needs to resolve in order to gain effective integration, interoperability. The S95 standard parts 1, 2 have been focused on providing a basis for these messages, but they do not provide all the structure and the World Batch Forum has developed the B2MML message structure. From our experience which we have implemented a number of S95 integrations we have found that these two standards (S95 and B2MML) provide a good basis for standard messaging providing usually 80% of the structure, but as would be expected there should be room for customization according to the different sites. Much discussion between leading end users applying these standards has taken place, especially around the mapping of S95 Process Segments to a structure in the SAP Recipe,


and the MES/ Manufacturing Plant Model (S88, S95 Part 3 etc). Figure 7 shows an example of a mapping, which has been the basis for the mapping at a number of different sites, and forms a good basis. Note this will vary from site to site and organizations, but end users with a common business system, will strive for common messages to be passed between the business system and manufacturing systems, and therefore an organization wide set of rules for the mapping will need to be set up.

ProcessCell

Production Schedule

Production Request

ProcessSegment(S95 Segment Requirement)

S95 Production ScheduleSAP PP-PI

Process Order

Process Instruction

Operation

Phase

EquipmentModule

ControlModule

S88 Physical

OperationSegment(S95 Segment Requirement)

Personnel Requirement

Consumable Expected Req.

Material Consumed Req.

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S88 Procedural

Control Recipe

BAPIControlRecipe.Request.Response

Procedure

Unit Procedure

Operation

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ProductSegment(S95 Segment Requirement)Control Recipe

Material Produced Req.

1..*

1..1

1..1

1..*

1..*

1..*

1..1

1..*

1..*

1..*

Equipment Requirement

1..1

1..*

1..1

1..*

1..*

1..*

1..1

Unit

Resource

1..1 1..1

1..*

1..*

Possible SAP PPPI to S88 Mapping

Figure 6 Wonderware has found that defining these mapping rules, and then business use cases as the most challenging part of any implementation especially the first project. In order to help with this Wonderware does offer consulting expertise to end-users and system integrators.

WWEI System Integrators Program

Due to the complex nature, the required business + manufacturing knowledge required to implement a successful Business System to Manufacturing System Integration, Wonderware has implemented a certification program for system integrators. The objectives of this program are:

• To establish a worldwide set of WWEI Certified System Integrators to support implementations of WWEI.

• To work with the end users, local Wonderware to determine the best qualified SI’s and then work with these SI’s in order to become certified. This will mean training and WW working as part of their team on the initial implementation.


This WWEI certification is a super set of the standard FactorySuite certification program, requiring that the SI be already certified in FactorySuite A2, as well as completing the necessary training for WWEI, and successfully implemented a WWEI application. Key in this certification is the ability for the SI to capture, and determine the best approach, business rules, and workflows required to marry the business system to the manufacturing system, as this varies which site and has been found to be where successful implementations are made or broken. Work with your local Wonderware contacts to jointly determine the system integration expertise in your local region. Summary: As you can see, Wonderware’s Enterprise Integration Application is a new generation of message integration software, providing unique flexible architectures, while maintaining ease of use, and the ability to reuse engineering. It enables you to avoid point-to-point systems, and get on with adding your domain expertise to the solution through graphical assembly of integration, leveraging proven integration adaptors to most applications. This solution can be combined with a Portal solution to provide powerful visualization of information Due to variations in how these solutions are applied and the different connectors required, if you are interested in understanding more, or want to know how Wonderware’s Enterprise Integration Application can be applied to solve your application, please contact your Wonderware sales contact, and an expert consultant will contact you.

(c) 2005 by Invensys Systems, Inc. All rights reserved. No part of this document may be reproduced, stored in or introduced into a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise), or for any purpose, without the express written permission of Invensys Systems, Inc. Invensys, Wonderware and ArchestrA are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners.

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