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MacLean-­Fogg Uses  
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  utili...
Industry  4.0  Meaning
• Established  2010
• Internal  lean  manufacturing  training
• Employee  empowerment
• Operator  =...
Opportunities
• Operational  unknowns
• Machine  efficiency
• Defect  rates
• Machine  downtimes
• Excess  inventory
• Qua...
Change  Model
business  needs
software hardware
.
visualization  of  accurate
real-­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  EdwardsPLCassets
Change  Model
.
Serial  Devices
• Less  than  50%  equipment  
connected
• Some  equipment  serial  
connected  via  outdated  
legacy  dr...
Kepware BizTalk JD  EdwardsPLCassets
Change  Model
Kepware
• Hub  for  real-­time  machine  communication
• Standardizes PLC  wire  protocols  to  OPC-­UA
• Bridges  shop  f...
• Topic  kepserver/0200/forming/1696
{
"timestamp":1443294150155,
"values":[
{"id":"0200_Forming.1696.GoodPieces","v":"138...
BizTalk JD  EdwardsPLCassets Kepware
Change  Model
Apache  
ActiveMQ
Kepware
JSON
kepserver/0200/forming/1696
MQTT  publis...
Change  Model
BizTalk JD  EdwardsPLCassets Kepware
• XML  messaging  platform
• Microsoft  SQL  backed
• Receive  and  sen...
Change  Model
BizTalk JD  EdwardsPLCassets Kepware
(typical  development  scenario)
change  model
BizTalk JD  EdwardsPLCassets Kepware
kepserver.*
JSON XMLreceive  pipeline
receive
port
processing  
orchest...
Enterprise  System
With  All  Needed  Modules
Change  Model
BizTalk JD  EdwardsPLCassets Kepware
.
Finance
Asset  Manageme...
Change  Model
BizTalk JD  EdwardsPLCassets Kepware
.
BizTalk
JDE
Custom
Function
Interoperability
Table
Backflush
Function...
Global  Architecture
Kepware
Kepware
factory  A
factory  Z
ActiveMQ
BizTalk
JD  Edwards
data  center
How  to  Start
• Start  where  you  know
• “Borrow”  hardware  from  
your  controls  engineer
• Write  some  MQTT  code
•...
How  to  Start
BizTalk JD  EdwardsPLCassets Kepware
• You’re  not  a  Microsoft  shop?
• My  personal  rapid  prototyping ...
Questions?
Kepware
BizTalkJD  Edwards
ActiveMQ
vendor  specific
MQTT
Payload  containing  work-­order,  employee,  and  pi...
Thank  You
cmisztur@macleanfogg.com
smasker@macleanfogg.com
sensing
interconnected
intelligent
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Smart Industry 2015: MacLean-Fogg Uses IIOT To Gain Industry Advantage

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Smart Industry 2015: MacLean-Fogg Uses IIOT To Gain Industry Advantage

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Smart Industry 2015: MacLean-Fogg Uses IIOT To Gain Industry Advantage

  1. 1. MacLean-­Fogg Uses   IIoT to  Gain  Industry   Advantage Chris  Misztur Scott  Masker with Tony  Paine
  2. 2. Agenda • Company  overview • Industry  4.0  meaning • Opportunities • Change  model • Global  architecture • How  to  start
  3. 3. 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
  4. 4. Industry  4.0  Meaning • Established  2010 • Internal  lean  manufacturing  training • Employee  empowerment • Operator  =  doing  +  thinking • Executive  backed operational   transformation information technology • ERP  implementation • Not  only  a  support  department • Value  add  opportunities • Innovation • Waste  elimination • Process  stability joint  effort
  5. 5. 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
  6. 6. Change  Model business  needs software hardware . visualization  of  accurate real-­time  information
  7. 7. The  Way  Forward . Change  Model assets PLC Kepware BizTalk JD  Edwards
  8. 8. • Started  at  1st process • Already  had  PLC • Internal  counters Kepware BizTalk JD  EdwardsPLCassets Change  Model .
  9. 9. 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 .
  10. 10. Kepware BizTalk JD  EdwardsPLCassets Change  Model
  11. 11. 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
  12. 12. • 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
  13. 13. BizTalk JD  EdwardsPLCassets Kepware Change  Model Apache   ActiveMQ Kepware JSON kepserver/0200/forming/1696 MQTT  publish JMS  API  subscribe IOT Gateway kepserver.* • process • store/forward • analyze
  14. 14. Change  Model BizTalk JD  EdwardsPLCassets Kepware • XML  messaging  platform • Microsoft  SQL  backed • Receive  and  send  ports • Orchestrations   • XLANG/s  BPEL • Messaging  language • C#  expression ü File ü FTP  (FTPS) ü HTTP(s) ü MSMQ ü POP3 ü SFTP ü SMTP ü SOAP ü WCF ü SB-­Messaging ü MQSeries ü SharePoint ü TCP-­IP  Socket ü Oracle ü SAP ü PeopleSoft ü JD  Edwards ü LDAP ü JMS ü RSS ü SSH ü AMQP ü XMPP ü Salesforce ü Dynamics  CRM ü Google ü Twitter ü Facebook ü Fax ü PowerShell ü ZeroMQ
  15. 15. Change  Model BizTalk JD  EdwardsPLCassets Kepware (typical  development  scenario)
  16. 16. change  model BizTalk JD  EdwardsPLCassets Kepware kepserver.* JSON XMLreceive  pipeline receive port processing   orchestration  BPEL JMS send ports JDE REPORT  PIECES COMPLETED SQL UPDATE  ASSET  OEE JMS ASSET  ACTIVITY cm (ALTERNATIVE)
  17. 17. Enterprise  System With  All  Needed  Modules Change  Model BizTalk JD  EdwardsPLCassets Kepware . Finance Asset  Management Order  Management Reporting Mobility Production Open  architecture  allowing  for  customization
  18. 18. Change  Model BizTalk JD  EdwardsPLCassets Kepware . BizTalk JDE Custom Function Interoperability Table Backflush Function Small  Data  Set   [WO  User Quantity  ] Enterprise   Data Completion Message JDE Custom Function BizTalk Completion  OK Or Errors  Reported
  19. 19. Global  Architecture Kepware Kepware factory  A factory  Z ActiveMQ BizTalk JD  Edwards data  center
  20. 20. How  to  Start • Start  where  you  know • “Borrow”  hardware  from   your  controls  engineer • Write  some  MQTT  code • Become  familiar  with   message  brokers
  21. 21. How  to  Start BizTalk 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
  22. 22. Questions? Kepware BizTalkJD  Edwards ActiveMQ vendor  specific MQTT Payload  containing  work-­order,  employee,  and  piece  information JMS Call  business  function Run  Backflush Process Business  function  response
  23. 23. Thank  You cmisztur@macleanfogg.com smasker@macleanfogg.com sensing interconnected intelligent

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