IIB Manufacturing Pack v1001

IIB Manufacturing Pack 1.0.0.1 Overview
IBM Integration Bus Manufacturing Pack
Dom Storey <dstorey@uk.ibm.com>

2
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GOVERNING THE USE OF IBM SOFTWARE.
Important Disclaimer

Background to Manufacturing Integration

Standards

Technologies

Products
IBM Integration Bus Manufacturing Pack
Internet of Things
Agenda

Business Imperatives in Manufacturing
 The Manufacturing world is moving from Mass Automation to Mass Customisation
 The importance of capturing the “green dollar” – climate and eco-sensitive consumers
 Demands for increased resource efficiency
– Scheduling of production processes for optimal use of resources
– Production Performance Analysis.
– Equipment effectiveness and predictive maintenance.
– Increased competition means manufacturers need to become increasingly dynamic – highly
responsive and re-configurable production facilities
– Efficient despatch of production orders
 Impact of BRIC and MINT economies and emergent middle class
 Globalisation of supply chains, global competition with lower labour costs
$

ISA 95 Purdue Model
 Defines 4 separate Levels in industrial companies
 Provides a simplified version of the Purdue Reference Model for CIM (Computer Integrated
Manufacturing)
 Also builds upon the MESA (Manufacturing Execution Systems Association) model for
activities in the manufacturing control domain
Level 0 / 1
Process Control
Level 2
Supervisory Controls
Level 3
Operations Management
Level 4
Business Logistics
Level 5
Inter-Company
OPC DA / HDA
OPC UA
ISA-95/
B2MML
RosettaNet
OAGIS
MIMOSA

“SMLC supports the manufacturing industry through pursuing a comprehensive technology that no one
company can undertake. Process control and automation systems implemented in piecemeal fashion will
continue to limit innovation and capability. SMLC will build the business, interoperability and technology
models, demonstrations, infrastructure, and project teams across multiple industry segments.”
Industrie 4.0
 Industrie 4.0 is a German government strategy for promoting the computerization of
traditional industries such as manufacturing.
 The 4.0 is refers to a heralded fourth great industrial revolution
– Industrial Revolution 1 – mechanisation of production using water and steam power (coal!)
– Industrial Revolution 2 – Mass production using electricity
– Industrial Revolution 3 – The digital revolution (electronics and IT)
– Industrial Revolution 4 – Machine To Machine communication, SOA loose coupling
 Industrie 4.0 is aimed at producing “Smarter Factories” which:
– Are more adaptable e.g. logistics processes which can automatically react to unexpected changes
in production levels
– Are more easily configurable and connected to back-end enterprise functions
– Use resources more efficiently e.g. machines that predict failures, trigger maintenance processes
autonomously
SMLC is a non-profit organization whose membership is
available to industry, university, government laboratory,
independent consultant and organization / consortia.
SMLC
Smart Manufacturing Leadership Coalition

7

PLC (Programmable Logic controllers)
 Talk to sensors and actuators

More actuators and sensors being built with in built Industrie 4.0 capability
 Integrated OPC Servers
Some Industrie 4.0 enabled devices

The OPC Foundation is a non-profit organization that maintains specifications on behalf of the industry.
Total OPC market has 2,500+ vendors, providing 15,000+ OPC enabled products.
OPC Foundation product catalog provides 1,500+ OPC enabled products
The 1st
specification, released in 1996 was for OPC Data Access
The 2nd
specification, released in 1998 was for OPC Historical Data Access
The 3rd
specification, released in 1999 was for OPC Alarms & Events
Most universally accepted standard for data exchange between:
 SCADA and HMI Systems
 PC-based control systems
 Manufacturing Execution Systems
Quick adoption of the original OPC Data Access specification was driven by:
 Windows Component Object Model (COM) and Distributed Component Object Model (DCOM)
Europe
(43%)
North
America
(39%)
Asia
(13%)
Others (5%)
App A App B
Server 1 Server 2 Server 3
OPC OPC
OPC
Server 1
OPC
Server 2
OPC
Server 3
App A App B
The OPC Foundation

The purpose of the OPC Unified Architecture was to enable a platform
independent interoperability standard for moving data between the factory floor
and the enterprise.
Contributions from over 30 companies over 5 years.
Specification first published in 2009
Original premise built on the existing OPC DA COM / DCOM based
specifications BUT improved some of its flaws:
 Platform dependence on Microsoft
 Insufficient data models
 Inadequate security
No reinvention! Standard builds upon other existing standards
OPC UA Server
OPC UA Client
Client
Requests
Server
Responses
Notifications

Most common services offered by an OPC UA Server:
 Discovery – Servers provide a Discovery Endpoint which can be
accessed directly or through a discovery server.
 Profile Support – So client devices can decide if the server can
support their needs – eg XML / Binary encoding and Security
 Address Space – Read properties of the available nodes, and
read and write attributes of the variable type nodes.
 Notification / Subscription – A client can define a set of nodes
which the server monitors for a specified condition(s) which
triggers a notification
+ +
OPC Unified Architecture

OPC Unified Architecture
Node
Node
Node
Node
Node
Node
Node
Node
Node
View
OPC UA AddressSpace
Monitored Item
Subscription
OPC UA Server
OPC UA Server API
OPC UA
Communication Stack
Request Response Subscribe Notify
From
OPC UA
Client
To
OPC UA
Client
From
OPC UA
Client
To
OPC UA
Client

OPC Data Access
 OPC DA, or OPC Classic as it is sometimes known, was born in the 1990s – system
integrators in the manufacturing industry were trying to incorporate the PC into factory
floor applications using serial port connections.
 Any application using a serial device was a candidate for a PC to replace a PLC, but
there was heavy dependence on writing drivers for the serial devices!
 Mission: create a way for applications to get at data inside an automation device
without having to know anything about how the device works
OPC Client
OPC Server
Vendor A
OPC Server
Vendor B
OPC Server
Vendor C
Item 2: Value, Quality, Timestamp
Group (public | local)
Device
The OPC Foundation provided a solution by combining Windows
COM with an API for device protocols.
Vendor explosion providing OPC Servers
• OSIsoft, Matrikon, Kepware, Honeywell
Vendor code determines the devices and data which the server
can access, details for how it does this, and naming conventions
for the OPC resources
Application Logic
COM interface
Application Logic
COM interface
COM interface
OPC Data
Proprietary Driver
MICROSOFT COM
Serial

OPC Classic versus OPC UA
DA
OPC UA Base
Vendor Specific Extensions
AC HA Prog
Specifications of Information Models
of other organizations
 Data Transport
 Security
 Information Modelling
OPC Overview
OPC Security OPC Common
Alarms & EventsHistorical DA
Data Access
PLC
Alarm Management Trend Display
COM / DCOM
OPC HDA Client
OPC HDA ServerOPC A&E Server
OPC A&E Client
DCS
OPC DA Client
COM / DCOM
OPC DA Server OPC DA Server
Vendor SpecificVendor Specific

OSIsoft PI Server
 Founded in 1980, HQ San Leandro California
– 1000+ professionals, 15,000+ customer installations across 110+ countries
 Approximately $270million revenue, 50% North America
OSIsoft
PI Server
PI Server
“interfaces”
“outerfaces”
PI Server has developed 400+ interfaces designed to gather data
from SCADA sources, convert to a PI readable format and then
send it to the PI Server to be stored. Example interfaces are OPC,
Modbus and PLCs.
Typically PI Server runs on a separate computer from PI Interfaces
and PI Client Applications.
A PI Server “Collective” describes an HA grouping of PI Servers
which can be considered as a single logical entity.
Elements are the building blocks
of a PI System. Structural
elements can be arranged into a
hierarchy, to represent a set of
organized objects. Equipment
List, Pumps, Tanks, Flow Meters
Heat Exchangers and Reactors
are all structural elements.

Manufacturing - Business Problems and IT Solutions
Rig
Mine
Factory
π r2
h
IIB
 Social is driving up expectations of real-time availability, data accuracy and types of information
available across Enterprise and Supply Chain
Security through physical system isolation is no longer viable
Market drive to exploit advances in IT Security, distributed and virtualised IT solutions
Production locations are typically isolated and heavily
silo-ed from IT Enterprise. Highly heterogeneous
systems environments; no two locations the same
Need to make detailed operational information
available to an ever increasing range of consuming
applications and users without compromising
production efficiency

Manufacturing and IBM Integration Bus
 IIB Manufacturing Pack
– Released 2Q 2014
– Fix Pack 1 4Q 2014
 Plant Connectivity De Facto Standards
– Connectors and patterns that support current OPC industry standards for
integration of plant and machinery data and events, including a small
number of vendor-specific implementations
 Plant Connectivity Emerging Standards
– Support for emerging OPC Unified Architecture standards to allow broader
integration to the enterprise
 Enterprise Connectivity
– Integrations and connectors, including MQ Telemetry Transport (MQTT),
which facilitate the transmission of data from remote locations
– Web-based interface to provide operational views of data published from
plant and machinery

Manufacturing Landscape
ODBC
JDBC
SQL
IBM Integration Bus in a Manufacturing context
Web Services
SOAP XML
Portal
Web Apps (internal)
IDOC, BAPI
Proprietary XML
Corporate Applications
ERP, Production Scheduling
Dynamics
Oracle
SAP
Web Services
HTTP, JMS
File, SQL
Web Services
SOAP, XML
Analytics
Manufacturing
Execution Systems
Decision Management
Product Quality
Management
Web Services
HTTP / JSON
Plant Staff
Mobile Applications
Supply Chain Management
Remote Telemetry Unit
SCADA
Web Services
IDOC, BAPI
SQL
MQTT
Remote Site
(satellite link)
OPC Classic Server
(including Historian)
OPC DA
OPC HDA
OPC AE
OPC UA
Asset Management
OPC
B2MML
Web Services
OPC UA Server
(including Historian)
Web Services
Proprietary
interfaces

IBM Integration Bus Industry Packs

Each pack is a fully supported software product, independently delivered from IBM
Integration Bus

The purpose of an IIB Industry Pack is to provide industry-specific development
accelerators which solve common industry integration problems

Help users to deploy working integration solutions in literally a few clicks of the mouse.

IIB Industry Pack content is structured around three delivery pillars:
Connectors
Data Definitions
Integration Patterns Monitoring
Association for Retail
Technology Standards
Open Applications Group
Data Format Description Language
Open Grid Forum
Health Level 7
Digital Imaging and Communication
in Medicine

Manufacturing Pack High Level Architecture

What does the Manufacturing Pack provide?
19
Contains several moving parts
– OPC UA Read Node/ OPC UA Input Node
– OPC Classic Read/ OPC Classic Write
– PI Read Node/ PI Input Node
– MQTT Nodes
– Factory Pattern
– Web UI
• Operational Monitoring
• Manufacturing Integration Monitoring
– Ability to use B2MML schemas (imported from http://www.mesa.org/en/B2MML.asp)

20
Manufacturing Pack OPC Classic Nodes

Output from the DA Read Node (TagData.xsd) can drive the DA Write Node
IBM Confidential

21
Manufacturing Pack OPC UA Nodes

Can dynamically connect to OPC UA sever to retrieve valid tags at design time

Used to configure the OPC UA Read and OPC UA Input nodes

Can connect securely with SSL

'opc.tcp' style connection only

22
Manufacturing Pack PI Nodes

Connect to your PI Server to retrieve series of PI Point tags

PI Read Node (PI SDK) and PI Input Node (PI AF SDK)

PI Input node allows wildcards

23
Manufacturing Pack Nodes Commonality

Output of the Manufacturing nodes in TagData.xsd format

Common for all Manufacturing nodes

Schema shipped in pattern: enables validation, with null support and mapping

All midflow manufacturing nodes now have 'invalid tags' terminal

Decide how to handle tags which cannot be found on your server

Manufacturing Pack example Flow and Output

Manufacturing Pack Factory Pattern

Use the Factory Pattern to expose your sensors

Produces IIB artifacts in a few clicks

Manufacturing Pack Web UI

B2MML to SAP

Future Roadmap (No priority order)
Integration Bus Nodes
– OPC Classic HDA
– OPC Classic AE
– OPC UA HDA
– OPC UA Write
– PI HDA
– PI Write
– S7 Siemens
IBM Confidential

Internet Of Things Forecast
2020 View
Source: IDC, December 2013
 212B Installed Things
 30B autonomously connected things
 Public Sector, Distribution & Services,
Manufacturing & Resources, and
Consumers Lead Segment Growth Rates
 Approximately 3 Million Peta Bytes Of
Embedded Systems Data (Excludes
Streaming, Surveillance Type Data
 $8.9Trillion Of Business Value

Sense and ControlSense and ControlVisualise and RespondVisualise and Respond
Intelligence
and Analytics
Traditional
Backend Systems Big Data
Sense
Data/Alert
Respond
Control
Sensor Area
Network
Home Area Network
Personal Area Network
Vehicle Area Network
Sensor Area
Network
Home Area Network
Personal Area Network
Vehicle Area Network
Edge Gateway
The Realm of the IoT
Connectivity
Things
Mobile
Cloud

MQTT and Remote Data Sources
Distance = > 250 km
Flow ControlPressureTemperatureOil Storage
Low-power, low-bandwidth / PLCs and RTUs
Upstream Center of
Operation and Control
Head office
IT Corporate Infrastructure
WAN

Central
Systems

Monitoring
- temp, pressure...

Control
- valves…
4000 devices integrated, need to add 8000 more BUT:
•Satellite network saturated due to polling of device
•VALMET system CPU at 100%
•Other applications needed access to data ("SCADA prison")
Proprietary polling protocol
Billing
Maintenance
SCADA
low-bandwidth,
expensive comms
Pipeline: integration challenges

Central
Systems
Billing
Maintenance
SCADA
low-bandwidth,
expensive comms
Scalability for whole pipeline!
Network traffic much lower - events pushed to/from devices and report by exception
Network cost reduced
Lower CPU utilization
Broken out of the SCADA prison – data accessible to other applications
Billing customers immediately after delivery
Message Broker
pub sub
transformation
Enterprise MessagingMQTT
20 Field
Devices to 1
Concentrator
Creating an Open SCADA Pipeline

IIB Manufacturing Pack v1001

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IIB Manufacturing Pack v1001