smart industry 2015: maclean-fogg uses iiot to gain industry advantage
TRANSCRIPT
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
• 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• Some equipment serial connected via outdated legacy drivers and software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
• 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
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
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