when data quality matters in process & manufacturing · – automatic execution of sigmafine...

Sigmafine, a Framework for Data and Business System Integration

… when Data Quality Matters in Process & Manufacturing

© Pimsoft Inc. – 2014 – Confidential – Do not reproduce without authorization

Luca Giovannoni and Massimo Galli, Pimsoft

Topics • Sigmafine, New Emerging Scenarios

• A Framework for Business Integration

• Some Practical Experiences

• Conclusion

11/5/2014 © Pimsoft Inc. – 2014 – Confidential – Do not reproduce without authorization

Sigmafine Shifting from an engineering app to a data quality service


Mass Balancing Application

Integrated Production Accounting Solution

Integrated Supply Chain and MES Context

Data Quality as a Service

Info

rmat

ion

Val

ue

Complexity of Data Model or Structure

Sigmafine New Emerging Scenarios


Complexity of

Architecture

Complexity of

Application

Completeness of

Service

© Pimsoft Inc. – 2014 – Confidential – Do not reproduce without authorization

MES

Performance Management

Balance & Accounting

Production Order Execution

Movement Management

Integration Framework

SAP

Planning and Scheduling

(SCM)

Budget & Forecasting

Process Variables Laboratory Analyses

Reci

pe

Managem

ent

Ware

house

M

anagem

ent

Main

tenance

Qualit

y

Managem

ent

Master Data Repository

11/5/2014

Sigmafine in New Emerging Scenarios Manufacturing Execution Systems

http://www.sap.com/index.epx

Sigmafine in New Emerging Scenarios Enterprise Architecture


HQ Infrastructure

Sigmafine Clients (HQ)

SQL Server

Site #1

SQL Server

Site #2

SQL Server

Site #n

SQL Server

Sigmafine in New Emerging Scenarios Enterprise Architecture

• Multiple Sites and Headquarters

• New Challenges – Scalability – High Availability

o on data o on application

– Consistency o master data management o synchronization


Sigmafine in New Emerging Scenarios Data Quality as a Service • Customers demand improvement in the quality of data feeding

their business systems:


“…business wants to validate the consumption of fuel against the production of Heat (city heating) and electrical power, in total 6 Power Plants are in scope…improving quality of data for billing …”

• Sigmafine is considered as the provider of a data quality service able to:

– Run automatically and unattended (no interaction with models)

– Retrieve automatically source data from external systems

– Provide self diagnostics and notifications

– Make validated data available to business systems

Sigmafine in New Emerging Scenarios Data Quality as a Service


In

teg

rati

on

Fra

me

wo

rk

Financials

Adjusted

Reconciled

Service

monitoring &

diagnostics

On-line raw data

(PI System)

GAS/Power Fiscal data (EMS/FILE)

Adjusted/ Manual data (DataLoader)

Final Data (Reports)

To Billing System

Sigmafine in New Emerging Scenarios Demand for Smarter Integration

• Online vs. offline

• Near real-time

• Timeliness

• Based on event (business rather than process)

• Configurable vs hard-coded

• Maintainable




• Runs on Windows Server 2003 and 2008

• Built on Microsoft .NET 3.x platform and Microsoft WCF

• Compliancy to standard XML Diffgramm Technology

• Available for AF 1.x and 2.x

• Support all AF object types, even custom templates

• Read and write PI & AF capabilities

• Support for reading/writing to PI System (Tags, ModuleDB and Batches)

OSIsoft Support

• Multi-connectors: All OLE-DB providers (tables, views, stored-procedures…), text and binary files, SOA (XML Web Service, WCF, SAP/XI, Biztalk, Tibco…)

• Fully compatible with Oracle portal, SAP Portal and PI WebParts Integration

• Connection pooling and data caching engine

• Scheduling (time/event), orchestration and data workflow services (read/write)

• Features for data casting, transformation and formatting

• Advanced customization features through scripting and custom plug-ins

Services

Manufacturing Execution System Order Execution – Posting Consumptions/Productions


Integration Logic

Sigmafine Server

SAP (PPPI)

SAP/MII

Web Service Connector

Production Integration

Rule

Consumption Integration

Rule

Manufacturing Execution System Order Execution – Posting Consumptions/Productions

• Business needs:

• Automatically feed SAP PPPI with reconciled (validated) production, consumption and utility data

• Post data into active Process Orders on order to monitor production on a daily basis

• Warehouses automatically synchronized within SAP

• Check expected yields with actual yields in SAP

• Benefits:

• Data posted upon production accounting confirmation (production owns data; finance and production controllers check)

• Daily posting of reconciled figures minimize the end of month “manual reconciliaiton”

• Transparent integration: reconciled productions and consumptions are automatically charged over active Process Orders by SAP/MII without user’s intervention

• Easy maintenance of the interface


Integration Logic

Sigmafine IMM

AspenTech APS

AspenTech Integration Framework (Web Service)

Web Service Connector

APS Events

(Receipt/Shipments)

Integration Rule

APS Streams

(Charge/Production)

Integration Rule

Stock Updates

Integration Rule

Event Updates

Integration

Rule

Manufacturing Execution System Integrating Refining Scheduling System

Manufacturing Execution System Integrating Refining Scheduling System • Business needs:

– Bi-directional integration between scheduling and operations. APS schedules refinery movements and Sigmafine IMM executes them

– After movement execution Sigmafine sends to APS the updated status for a new APS plan

– Import in Sigmafine information needed for tracking the execution in detail: plannned quantity, start/end time… etc

– Align automatically APS with the real refinery status

• Benefits: – Automatically feed Sigmafine IMM with movement plan eliminating guesswork (more

than 300 movements par day) and allow quicker and better tracked oil movement operations

– Automatic alignment of movement with real movement status and stock situation lead to improve APS planning with less manual inputs

– Automatic interface allow sending more APS plans par day with a single click, overriding the previous plans

– Improved management of forced replanning


Integration Logic

Sigmafine Server

Heat Meters

File Connector

Heat Meter

Integration Rule

Energy Meter

Integration Rule

Energy Meters Gas Meters

Gas Meter

Integration Rule

Providing Data Quality as a Service Automating the Sigmafine Process

Providing Data Quality as a Service Automating the Sigmafine Process

• Business needs: – Perform a fully integrated energy balance (Heat + Energy + Gas) around power facilities

with multiple exchanges with gas-feeding, tele-heating and energy grids

– Data are provided in different formats (different files), frequency (daily, weekly, monthly…etc) and granularity (15 and 60 minutes): provide a unique and homogeneus layer for integrating all data needed for balance

– Easy, quick and automatic recovery features

• Benefits: – Automatic execution of Sigmafine energy balance for power-plant facilities

– IF acts as a “listener”: as soon as new data are available, they are automatically imported and balance is executed (or re-executed in case of new set of historical data)

– No more Excel painful spreadsheets: automatic formats and data conversions leading a more standard and manageable balance

In Summary • IF is the foundation for integration:

– configurable – maintenable – robust

• Supporting the delivery of Data Quality: – as an Enterprise Application – as a Service


Thank you! [email protected]

[email protected]


mailto:[email protected]



when data quality matters in process & manufacturing · – automatic execution of sigmafine...

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