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SIMATIC IT Production Modeler SIMATIC IT Product Definition Manager SIMATIC IT Material Manager
Technical Overview
Function Manual
SIMATIC IT Production Order Manager SIMATIC IT Personnel Manager SIMATIC IT Shift Calendar SIMATIC IT Data Integration Service SIMATIC IT Client Application Builder SIMATIC IT Historian
Edition 10/2007
A5E01140770-01
Guidelines
This manual contains notices intended to protect the products and connected equipment against damage. These notices are graded according to severity by the following texts: Caution Indicates that if the proper precautions are not taken, this can result into property damage. Notice Draws your attention to particularly important information on handling the product, the product itself or to a particular part of the documentation.
Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
A5E01140770-01 10/2007
Preface
Purpose
This Function Manual explains the fundamental concepts, features and functionalities provided by SIMATIC IT Production Suite. Important This guide does not intend to describe how to use and configure each SIMATIC IT component. For more information concerning the configuration and use of the components see the related help online documentation. (Start > SIMATIC > SIMATIC IT Documentation).
Readme
The installation includes a readme file, which contains information on upgrade procedures and compatibility with previous releases. This file is supplied both in standard text (Readme.wri) and in Acrobat PDF (Readme.pdf) format. This file is available in folder \ReleaseNotes of the setup DVD and is available from the shortcut Start > SIMATIC > SIMATIC IT Documentation.
Online help
The online helps of SIMATIC IT, which is integrated in the software, complements this Function Manual and provides you with detailed support for using the software. These helps are all available online from the shortcut Start > SIMATIC > SIMATIC IT Documentation. The help system consists of: The Contents and Index command on the Help menu to open the online help window, from which you can choose the topic of interest. You can search for the desired information, using the table of contents or the index A context-sensitive help that offers information on the current context, for example, an open dialog box or an active window. You can open the contextsensitive help by clicking the Help button in any dialog box.
SIMATIC IT V6.3 SP1 A5E01140770-01 iii
Preface A status bar that offers another type of context-sensitive help. It displays a short explanation for each menu command when the mouse pointer is positioned on the menu command. A brief explanation (ToolTip) for each icon in the toolbar when the mouse pointer is positioned on the icon for a short time.
Related documentation
The following documents contain information related to the content of this Function Manual: SIMATIC IT Configuration Manual SIMATIC IT Installation Manual SIMATIC IT Licensing Configuration Manual Best Practices Configuration Manual SIMATIC IT Application Deployment Configuration Manual KPI Management Configuration Manual Client Application Builder Concept Guide Client Application Builder Portal Startup Guide Client Application Builder Portal Developer Manual Client Application Builder Visual Composer User Manual Client Application Builder Good Programming Practice Developer Manual Data Integration Concept Guide Data Integration Service Tips and Tricks User Manual Historian Concept Guide Historian Data Recovery Management User Manual All these documents are available online from the shortcut Start > SIMATIC > SIMATIC IT Documentation.
Conventions
The table below describes the specific typographic conventions that are used throughout this manual:
Symbol/Convention Indicates...
Where examples are given. The names of menus, commands, dialog boxes and toolbar buttons and, in general, all strings (e.g. File menu; Save command). Shortcut keys, which permit rapid access to commands (e.g. CTRL+C). The names of keyboard keys (e.g. RETURN key).
KEY1+KEY2 UPPERCASE
iv
Preface
Symbol/Convention Indicates...
Italics
The names of parameters that must be replaced with a specific name or value. E.g. filename indicates that the name of the file must be specified; input indicates that the corresponding value must be specified.
>
A succession of commands in which the command preceding the symbol must be selected before the command following it.
Preface Hot fixes (officially tested and released) are not shipped and must be downloaded from the Technical Support Service Web site.
The following options are available: Standard support: 9 hours/day, 5 days/week Premium support: 24 hours/day, 5 days/week Advanced support: 24 hours/day, 7 days/week
The principal language of the SIMATIC IT hotline is English. SIMATIC IT partners and customers covered by the Software Maintenance program are entitled to direct access to the TSS.
Online Support
A customer who is a registered TSS user, can access the Technical Support Web site (http://www.siemens.com/mes-simaticit/tss), which contains technical information such as: Service conditions (Phone numbers, Working hours, Reaction times,) SIMATIC IT knowledge base: a technical support database that includes practical service solutions from the Technical Support or the SIMATIC IT community SIMATIC IT software (e.g. hot fixes, software examples) and release notes that can be downloaded SIMATIC IT cross-industry libraries that can be downloaded (limited access to SIMATIC IT certified partners) SIMATIC IT product documentation that can be downloaded Frequently Asked Questions and useful tips.
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Table of Contents
1 Overview...............................................................................................................................1-5 1.1 General Architecture...................................................................................................... 1-5 1.1.1 Manufacturing Execution System .....................................................................1-5 1.1.2 A 3-Tiered Distributed System ..........................................................................1-6 1.1.3 Layered Service System ...................................................................................1-7 1.2 Main Functionality .......................................................................................................... 1-8 1.2.1 SIMATIC IT .......................................................................................................1-8 1.2.2 SIMATIC IT Components..................................................................................1-9 1.2.3 SIMATIC IT Historian ......................................................................................1-10 2 Production Information Management................................................................................ 2-1 2.1 Introduction .................................................................................................................... 2-1 2.1.1 Generic Activity Model ......................................................................................2-1 2.2 Defining Operations Capability (Production Resource Management)........................... 2-2 2.2.1 Equipment Resource Information Management ...............................................2-3 2.2.2 Material Resource Information Management....................................................2-4 2.3 Defining Operations (Product Definition Management) ................................................. 2-5 2.3.1 Primary Tasks ...................................................................................................2-5 2.3.2 Collaborative Manufacturing .............................................................................2-6 2.3.3 Interfaces to Product Definition Management...................................................2-7 2.4 Defining Operations Request (Detailed Scheduling and Dispatching) .......................... 2-7 2.4.1 Production Dispatching .....................................................................................2-7 2.5 Production Execution Management............................................................................. 2-10 2.5.1 Primary Tasks .................................................................................................2-10 2.5.2 Collaborative Manufacturing (Integration Strategies) .....................................2-11 2.6 Operations Response (Tracking, Data Collection, Analysis)....................................... 2-13 2.6.1 Primary Tasks .................................................................................................2-13 2.6.2 Collaborative Manufacturing ...........................................................................2-14 3 SIMATIC IT Production Modeler......................................................................................... 3-1 3.1 Software Architecture .................................................................................................... 3-1 3.2 Project Management...................................................................................................... 3-2 3.2.1 System files.......................................................................................................3-2 3.2.2 Project files........................................................................................................3-2 3.2.3 Version Files .....................................................................................................3-3 3.3 Production Modeler Environment .................................................................................. 3-3 3.3.1 External Connections Environment ..................................................................3-3 3.3.2 Libraries Environment .......................................................................................3-4 3.3.3 Plants Environment...........................................................................................3-4 3.3.4 Runtime Environment .......................................................................................3-4 3.4 Basic Concepts .............................................................................................................. 3-4 3.4.1 Equipment Hierarchy Model..............................................................................3-5 3.4.2 Process Segment Model...................................................................................3-5 3.4.3 Logical Classes.................................................................................................3-6 3.4.4 Class Members .................................................................................................3-6 3.4.5 Equipment Rules...............................................................................................3-6 3.4.6 Plant ..................................................................................................................3-7 3.4.7 Master and Execution Copies ...........................................................................3-7 3.5 Modeling the Enterprise................................................................................................. 3-7 3.5.1 Creating the Plant Library .................................................................................3-7 3.5.2 Versioning of User Industry Libraries................................................................3-8 3.5.3 Life Cycle of User Industry Libraries.................................................................3-8 3.5.4 Adding Sub-Libraries ........................................................................................3-8
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Table of Contents 3.5.5 Protecting Library Rules....................................................................................3-9 3.5.6 Creating a Library Class ...................................................................................3-9 3.5.7 Configuring the Class Template .....................................................................3-10 3.5.8 Populating the Class Contents .......................................................................3-10 3.5.9 Working with Class Members .........................................................................3-10 3.5.10 Synchronizing Library Instances .....................................................................3-12 3.5.11 Working with Process Segment Classes ........................................................3-12 3.6 Engineering the Plant .................................................................................................. 3-15 3.6.1 Instantiating the Plant .....................................................................................3-15 3.6.2 Working with the Plant Equipment..................................................................3-15 3.6.3 Working with Plant Process Segments...........................................................3-16 3.6.4 Versioning of the Plant....................................................................................3-16 3.6.5 Life Cycle of Plants .........................................................................................3-17 3.6.6 Synchronizing Instances .................................................................................3-17 3.7 Operating the Business Flow....................................................................................... 3-17 3.7.1 Setting the Plant Version to Share..................................................................3-17 3.7.2 Enabling/Disabling the Plant ...........................................................................3-18 3.7.3 Pausing/Resuming the Plant...........................................................................3-18 3.7.4 Aligning Data in the Components Database...................................................3-18 3.8 Interacting with Operators............................................................................................ 3-19 4 SIMATIC IT Product Definition Manager ........................................................................... 4-1 4.1 Software Architecture .................................................................................................... 4-1 4.2 Basic Concepts .............................................................................................................. 4-1 4.2.1 Product Production Rules .................................................................................4-2 4.2.2 Product Segments ............................................................................................4-2 4.2.3 Product Segment Resources ............................................................................4-2 4.3 Engineering Activities .................................................................................................... 4-2 4.3.1 Creating Product Production Rules ..................................................................4-2 4.3.2 PPR Life Cycles ................................................................................................4-4 4.3.3 Versioning of a PPR..........................................................................................4-5 4.3.4 Creating Standard Product Segments ..............................................................4-5 4.3.5 Health Checking................................................................................................4-6 4.4 Using PDefM Display..................................................................................................... 4-6 4.5 Using GSI SIT Methods ................................................................................................. 4-7 4.6 Importing Data from via B2MML .................................................................................... 4-7 5 SIMATIC IT Material Manager ............................................................................................. 5-1 5.1 Software Architecture .................................................................................................... 5-1 5.2 Basic Concepts .............................................................................................................. 5-1 5.2.1 Material Model ..................................................................................................5-1 5.2.2 Bill of Material ...................................................................................................5-2 5.2.3 Location.............................................................................................................5-2 5.2.4 Handling Units...................................................................................................5-2 5.2.5 Properties..........................................................................................................5-2 5.3 Engineering Activities .................................................................................................... 5-3 5.3.1 Defining the Material Model ..............................................................................5-3 5.3.2 Versioning of Material Definitions .....................................................................5-3 5.3.3 Handling Material Definition Status...................................................................5-4 5.3.4 Defining Material Hierarchies............................................................................5-4 5.3.5 Handling Bill of Materials ..................................................................................5-4 5.3.6 Handling Bill of Material Items ..........................................................................5-5 5.3.7 Handling Hut Types ..........................................................................................5-5 5.3.8 Defining Locations ............................................................................................5-6 5.3.9 Handling Properties ..........................................................................................5-6 5.4 Runtime Operations....................................................................................................... 5-7 5.4.1 Handling Lots ....................................................................................................5-7 5.4.2 Handling Lot Status...........................................................................................5-7 5.4.3 Consuming/Supplying Lot Quantity ..................................................................5-8 5.4.4 Working with Genealogy ...................................................................................5-8
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Table of Contents 5.4.5 Creating Handling Units ..................................................................................5-13 5.4.6 Charging/Discharging Huts .............................................................................5-13 5.4.7 Working with Hut Status..................................................................................5-13 5.4.8 Moving Operation............................................................................................5-14 5.4.9 Handling Property Values of Lots and Huts....................................................5-14 5.4.10 Reading the Lot History ..................................................................................5-14 5.4.11 Working with Sublots ......................................................................................5-15 Using MM Display........................................................................................................ 5-15 Using MM GSI SIT Methods ........................................................................................ 5-15 Importing Bulk Data through Fast Data Import ............................................................ 5-15 5.7.1 Importing Data from External Systems via B2MML ........................................5-16 Extending Material Manager with Custom Objects...................................................... 5-17
6 SIMATIC IT Production Order Manager............................................................................. 6-1 6.1 Software Architecture .................................................................................................... 6-1 6.2 Basic Concepts .............................................................................................................. 6-1 6.2.1 Order Hierarchy Model......................................................................................6-1 6.2.2 Time Frames .....................................................................................................6-2 6.2.3 Families and Types...........................................................................................6-2 6.2.4 Life Cycles.........................................................................................................6-2 6.2.5 Custom Properties ............................................................................................6-3 6.3 Engineering Activities .................................................................................................... 6-3 6.3.1 Creating Time Frames ......................................................................................6-3 6.3.2 Creating Families and Types ............................................................................6-4 6.3.3 Defining Custom Life Cycles.............................................................................6-4 6.3.4 Creating Custom Properties..............................................................................6-5 6.3.5 Creating Orders from PPR................................................................................6-6 6.4 Runtime Operations....................................................................................................... 6-8 6.4.1 Modifying Order/Entry Quantity ........................................................................6-8 6.4.2 Splitting Entries .................................................................................................6-9 6.4.3 Accessing Runtime Values ...............................................................................6-9 6.4.4 Handling Status Change ...................................................................................6-9 6.4.5 Archiving Data...................................................................................................6-9 6.5 Using the POM Display.................................................................................................. 6-9 6.6 Using POM GSI SIT Methods...................................................................................... 6-10 6.7 Managing Operations through the Campaign Tree and Private Xml........................... 6-10 6.8 Importing Data from External Systems via B2MML..................................................... 6-10 6.9 Extending Orders and Entries with Custom Objects ................................................... 6-11 7 SIMATIC IT Personnel Manager ......................................................................................... 7-1 7.1 Personnel Management................................................................................................. 7-1 7.2 Feature Highlight ........................................................................................................... 7-1 8 SIMATIC IT Shift Calendar .................................................................................................. 8-1 8.1 Overview ........................................................................................................................ 8-1 9 SIMATIC IT Data Integration Service ................................................................................. 9-1 9.1 Overview ........................................................................................................................ 9-1 9.2 Software Architecture .................................................................................................... 9-1 9.3 Connector Support......................................................................................................... 9-2 10 SIMATIC IT Client Application Builder ............................................................................ 10-1 10.1 Software Architecture .................................................................................................. 10-1 10.1.1 CAB Environments..........................................................................................10-1 10.1.2 CAB Data Access Strategies ..........................................................................10-1 10.1.3 Basic Runtime Architecture.............................................................................10-1 10.1.4 CAB Portal ......................................................................................................10-2 10.2 Developing CAB Web Pages....................................................................................... 10-3 10.2.1 Data Access....................................................................................................10-3 10.2.2 Business Logic Execution ...............................................................................10-3
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Table of Contents 10.2.3 Security ...........................................................................................................10-4 11 SIMATIC IT Historian ......................................................................................................... 11-1 11.1 Overview ...................................................................................................................... 11-1 11.2 Plant Performance Analyzer ........................................................................................ 11-1 11.3 Historian Data Display (HDD) ...................................................................................... 11-2
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Overview
1.1
General Architecture
The SIMATIC IT architecture has been defined according to some of the most commonly used architectural patterns regarding layered and tiered systems, where: A layer shall be defined as the logical structuring mechanism for the elements that make up the software solution; it deals with the logical structuring of the software application into layers A tier shall be defined as the physical structuring mechanism for the system infrastructure; it explores the physical distribution of the system modules into tiers Furthermore, SIMATIC IT is thought to cover the Manufacturing Execution System (MES) functional requirements as defined by the ISA S95 standard. This means that the criteria in implementing the primary software activities is driven by the functions defined by ISA S95 about Level 3 activity management involved in manufacturing. From this point of view, SIMATIC IT presents also a functional structuring mechanism for the various server applications that make up the software solution. The following sections try to give an overview of these architectures which describe SIMATIC IT including also an overview on how all Production Suite components collaborate together.
1.1.1
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Table of Contents
As shown in the picture above, even if the definition and the interface with Control Level is out of the ISA S95 scope, SIMATIC IT, being part of the Totally Integration Automation (TIA) strategy, meets the automation requirements of interface between Management (MES) and Control Level. The information flows between the Level 3 and dependent Level 2 is supplied by the execution management activity which includes selecting, starting and moving those units of work (for example lots, sublots, or batches) through the appropriate sequence of operations to physically produce the product. The actual work (manual or automatic) is part of the Level 2,1,0 functions.
1.1.2
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Table of Contents
As from the diagram: Presentation (or Client) tier; it provides the application's user interface (UI). Typically, this involves the use of standard Windows applications and/or ASP.NET technologies for browser-based interaction. Business (or Application) tier; it implements the business functionality of the system. It includes a number of components that provide the ISA S95 specific functionalities and Production Modeler for coordinating their activities. Data tier; applications must access data stored in various repositories, which are most often relational databases. Data access components in this data tier are responsible for exposing the data stored in these databases to the business tier.
1.1.3
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Table of Contents The available Services in SIMATIC IT are logically grouped in the following categories: Communication Services Security Services Compliance Services Diagnostic Service Object Service These services are logically distributed on three different layers (refer to following picture). General-purpose Services are in the lower layer, while MES specific functionalities are provided by Services in the upper layers. The main functionalities offered by each Service are listed in the following paragraphs.
Communication Services
RIS (Redundant Interprocess communication Server): manages TCP/IP based interprocess communications on redundant network (i.e. by using two standard network adapters). NCSERV (Network Configuration Server): manages and shares the network configurations information among all SIMATIC IT modules IPC (Inter Process Communication): used to establish and manage client/server communications DS (Discovery Service): used by client applications in order to get the location of server modules
Security Services
RAC (Remote Access Control Server): manages and shares the user and access rights info among all SIMATIC IT modules UM (User Management): this service manages SIMATIC IT users (e.g. defining, modifying, deleting users groups and scenarios, or policy account settings) AC (Access Control): service used by consumer applications in order to check user rights against requested actions
Compliance Services
AT (Audit Trail): this service is used in order to create Audit Trail records and store them in a secure repository ES (Electronic Signature): service used by consumer applications in order to manage the approval of actions performed on the MES system.
1.2
1.2.1
Main Functionality
SIMATIC IT
SIMATIC IT functionality is provided by means of the following software:
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Table of Contents SIMATIC IT Production Modeler (PM): is a modeling environment in which the functions, belonging to different SIMATIC IT Components, are combined graphically in order to explicitly define the business execution logic of the SIMATIC IT application. SIMATIC IT components: provide basic functionalities according to the S95 standard. Each component addresses specific manufacturing issues (e.g.: Order Management, Material Management, Personnel Management, Report Management, etc.). SIMATIC IT Historian: is a dedicated component to manage historical data. SIMATIC IT Report Manager: is a general purpose reporting tool that can be installed as a product option with SIMATIC IT Historian, Framework and Components. It is also able to integrate with other software products of the SIEMENS family as UNILAB and INTERSPEC.
1.2.2
SIMATIC IT Components
Here follows the list of SIMATIC IT components: SIMATIC IT Business Process Modeler (BPM) is an application server providing methods used by the system to maintain the alignment between the Production Modeler equipment data and the SIMATIC IT components database equipment data. Actually, it allows sharing equipment resource information with the other components. SIMATIC IT Material Manager (MM) is an S95 compliant MES component which manages material resource information on the SIMATIC IT components database. SIMATIC IT Personnel Manager (PRM) is an S95 compliant MES component which manages human resources on the SIMATIC IT components database. SIMATIC IT Product Definition Manager (PDefM) is an S95 compliant MES component which manages product definition information. SIMATIC IT Production Order Manager (POM) is an S95 compliant MES component which manages production-related orders on the SIMATIC IT components database. SIMATIC IT Shift Calendar Manager (SHC) gives the ability to share among other components (e.g.: PRM, PDS-I, OEE product option and so on) common definitions of calendars and work shifts for the management of resources. SIMATIC IT Client Application Builder (CAB) is a platform to develop graphical user interfaces focused on displaying MES specific data. SIMATIC IT Data Integration Service (DIS) is a service that enables XML based data exchange with external systems. SIMATIC IT Predictive Detailed Scheduler-Interactive (PDS-I) is the product option of SIMATIC IT Production Suite. It represents the S95 compliant MES components which manages detailed production scheduling information. SIMATIC IT Production Operation Recorder (POPR) is responsible for tracing on SIMATIC IT components database each production step executed by production Modeler. Usage of this module is deprecated: it is linked with the old PO=Production Operation concept and is kept only for backward compatibility.
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Table of Contents
1.2.3
SIMATIC IT Historian
SIMATIC IT Historian consists of: SIMATIC IT Plant Performance Analyzer (PPA) is capable to perform historical data collection, processing and management. SIMATIC IT Long Term Archiving (LTA) gives the capability to maintain a long history of all data collected and processed by PPA. SIMATIC IT Historian Data Display (HDD) is the sub-component for historical data visualization. SIMATIC IT Process Data Archive (PDA) is able to collect raw process data provided by the RTDS service and archive them in proprietary data storage accordingly to configurable data compression policies. SIMATIC IT Overall equipment effectiveness and Down time manager (OEE/DTM) is the product option of SIMATIC IT Historian for the standard computation of equipment efficiency reports. SIMATIC IT Statistical Process control (SPC) is the product option of SIMATIC IT Historian for the acquisition of process-quality relevant data and the computation of standard-based statistical calculation
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2.1
Introduction
The following sections try to summarize how production information flows in the SIMATIC IT Production Suite during the development of a MES solution. SIMATIC IT Production Modeler and Components works strictly together in order to fulfill the MES functional requirements as defined in the ISA95 standard. The way production information is managed throughout SIMATIC IT can be represented by the generic activity model of manufacturing operations management defined in the ISA95 standard.
2.1.1
2-1
Table of Contents The ovals in the model indicate collections of tasks, identified as the main activities and normally accomplished by the interaction of the totality of the Production Suite components. Lines with arrowheads indicate a set of important information flows between the activities. As from the ISA 95 standard, the collections of tasks involved in MES are summarized as follows: Production resource management can be defined as the collection of activities that manage the information about resources required by production operations Product definition management can be defined as the collection of activities that manage all of the Level 3 information about the product required for manufacturing, including the product production rules. Detailed production scheduling shall be defined as the collection of activities that take the production schedule and determine the optimal use of local resources to meet the production schedule requirements. Production dispatching shall be defined as the collection of activities that manage the flow of production by dispatching production to equipment and personnel. Production execution management shall be defined as the collection of activities that direct the performance of work, as specified by the contents of the production dispatch list elements. Production data collection shall be defined as the collection of activities that gather, compile and manage production data for specific work processes or specific production requests.
2.2
2-2
Table of Contents
Also the Business Level is allowed to access this information in order to analyse the production capability, which indicate what is currently available for use. The relation with the Business Level is bidirectional as the data can come also from the business systems through the provided production resource interfaces. As to this, each component has its own method of communication which makes possible the integration of information within the entire Suite environment.
2.2.1
Primary Tasks
As to equipment resource, SIMATIC IT Production Modeler (PM) is the main component involved in the equipment information management as it fulfills to the following tasks: Definition of the Equipment Hierarchy Model (as defined by ISA95) Definition of the Process Segment Model (as defined by ISA95, except for Personnel Resources)
Collaborative Manufacturing
Being based on a multi-platform solution, PM deals with proprietary KB data which must be provided in a format recognizable to the other components of the Suite. This is the main reason why PM relies on BPM: 1. Through PM, the equipment and process segment models are defined. 2. Then, through BPM data is made visible to the other SIMATIC IT components. Data is stored in the BPM repository which shall be defined as the collection of
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Table of Contents tables dedicated to the plant data inside the SIMATIC IT components database.
2.2.2
Primary Tasks
As to material resource, SIMATIC IT Material Manager is the component of the Suite dedicated the implementation of the material model and to the management of the material information. Briefly, the primary tasks performable by MM are: Definition of the material model, also with data coming directly from the Business Level Tracing of past, current and future material availability Tracing of material genealogy, performable during the execution phase of the dispatched work directly by the execution management system Exposure of data to Business Level systems
Collaborative Manufacturing
Being founded on a client-server architecture MM provides a set of functions (objects, methods, events and properties) able to perform the tasks related to the material resource management and store data in a specific repository dedicated to the material information. The following diagram, shows the basic data flow related to MM activities:
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Table of Contents As from the diagram: MM main task is to store material information in the MM repository. The MM repository can be defined as the collection of data tables inside the SIMATIC IT Components generic database dedicated to the storage of the material information. MM is able to use information about the equipment hierarchy model stored in the BPM repository in order to import the entire objects hierarchy, or a part of it, as common locations. Locations can be used inside MM to make symbolic associations of lots and handling units to pieces of equipment.
2.3
2.3.1
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2.3.2
Collaborative Manufacturing
PDefM is founded on a client-server architecture where the provided functionality is exposed by means of a set of functions able to perform the tasks related to the product definition management and store data in a specific repository dedicated to the product definition information:
As from the diagram, PDefM is able to: Manage product definition information through a dedicated repository. .The PDefM repository shall be defined as the collection of specific tables dedicated to the storage of product definition data placed inside the SIMATIC IT components database.
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Table of Contents Check data consistency between the resources indicated in the product definition data and the equipment, materials and personnel data stored in the repositories of BPM, MM and PRM. Checking is made possible by executing a specific operation named health check.
2.3.3
2.4
2.4.1
Primary Tasks
Production dispatching in the Suite is accomplished by SIMATIC IT Production Order Manager.
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POM primary tasks are: Management of work orders and dispatch lists Creation of orders assigning local resources to production as defined by product definition information Check the production resource availability Modify dispatch lists according to the production resource availability. Dispatch production to start in production lines defined in the execution system Interface dispatching to detailed scheduling systems, where detailed scheduling may come directly from the Business Level systems Note Detailed scheduling information management is provided by the product option Predictive Detailed Scheduler Interactive (PDS-I). PDS-I supplies detailed scheduling requirements by arranging orders and entries of the POM in a production schedule with associated estimated start, stop dates and resource usage. These resources must satisfy a given set of scheduling constraints (precedence and dependencies, capacity constraints, custom defined constraints). Such functionality is provided only by an interactive Gantt-chart supported by automatic constraint verification logic.
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Collaborative Manufacturing
POM is founded on a client-server architecture where the provided functionality is exposed by means of a set of functions (objects, methods, events and properties) able to perform the tasks related to production dispatching and store data in a specific repository dedicated to the work orders information:
As from the diagram, POM: Manages a dedicated repository about production request information. The POM repository shall be defined as the collection of tables dedicated orders data placed inside the SIMATIC IT components database Is able to create work orders from PPRs available in the PDefM Check the availability about equipment and materials from the production resource Define and schedule dispatch lists to start in process segments defined in PM
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2.5
2.5.1
As to execution management, PM primary tasks are: Implement custom business logic Start of Process Segments according to dispatch list coming from the dispatching system Parallel execution of the plant activities defined in the various pieces of the equipment as coordinated by the Process Segments or other external agents Performing the various plant execution works in separated execution copies Direction of the performance work with initialization of Control Level activities. Correct use of the resources during the production execution Ensure that the resource are valid for the assigned tasks Exchange information with production resource systems Provide production information and events on production execution management, such as timing, yields, labor and material used, start of runs, and completion of runs.
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2.5.2
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Phase level (Intermediate): SFC Types Integration enables SIMATIC IT to access control system functions directly through Production Modeler without an intermediate batch layer. This approach is particularly useful for managing continuous and discreet processes and also simple batch processes. This kind of communication is made possible by means of the SFC GSI Interface and the SFC Library. Batch level (Highest): Batch-related events and methods can be transferred from SIMATIC BATCH to SIMATIC IT Production Modeler and Plant Performance Analyzer. Additionally, the SIMATIC BATCH Library allows Production Modeler to call SIMATIC BATCH methods from rules thorugh the Batch GSI Interface. As to Variable/Message level of the integration it is important to note the PM is able to access RTDS variables through the SIMATIC IT Interface (GSI). In PM tags are handled in either of two approaches: Predefining a set of cube variables (i.e class attributes of type CUBEVARIABLE) which do not exist in the RTDS data dictionary, then download them into RTDS and create new tags.
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Table of Contents Defining a set of cube variables which already exist in the RTDS data dictionary, then link them with the RTDS tags. Directly accessing RTDS tags by means of ad-hoc scripts, using the ScriptCaller object.
2.6
2.6.1
Historian primary tasks are: Perform aggregations and analysis on historical data to provide performance statistics Perform and visualize KPI calculations on the base of KPI schedules coming from the execution system Collect, retrieve and archive information related to the execution of production requests and resource usage Provide collected product quality information for comparison against specifications Provide data monitoring about production execution Monitor and archive WINCC and third-party alarm events Provide reports on production data
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Table of Contents
2.6.2
Collaborative Manufacturing
As to SIMATIC IT Historian, the main component involved in the MES collaborative manufacturing system is SIMATIC IT Plant Performance Analyzer.
As from the diagram, PPA: Manage a dedicated repository for historical data, through a set of online and offline databases. In the diagram, the repository is highlighted in aqua, as is not located in the SIMATIC IT components database as BPM repository is. Can import equipment and KPI data from the BPM repository. Activates KPI calculations based on the schedules coming from PM, tracking product operation data Uses RTDS as real-time data source to sample real time values through data archiving tags Uses PDA as historical data source of compressed raw data
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3.1
Software Architecture
The following diagram shows the simplified architecture of SIMATIC IT Production Modeler (PM):
As from the diagram, PM is composed of: Production Modeler Server which coordinates and synchronizes the functional components in accordance with business logic operations. Data is stored in a proprietary repository by means of KB files (i.e. Knowledge Base). Production Modeler Client which supplies the Libraries, Plants, External Connections and Runtime graphical environments, in order to manage KB data such as project settings, user libraries and plants Production Modeler GSI Interface provides a well performing interface based on the proprietary GSI (Gensym Interface) TCP/IP based communication protocol. Also a COM Server is available in order to supply COM capabilities to PM Server, allowing creating, deleting and managing COM compliant applications. As PM saves the defined models in a proprietary format known as Kb data files (or Knowledge Base), in order to expose this data to other components of the Suite it works strictly together with another component: SIMATIC IT Business Process Modeler (BPM). PM relies on BPM about sharing equipment resource information with the other components. Actually, the BPM component: Establishes the information about the equipment resources which must be shared in the collaborative manufacturing environment of the MES solution Synchronizes equipment data to the PM modeled data according to user conditions
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Table of Contents Since a copy of the original model is present in the BPM repository, the communication between PM and BPM is crucial in order to maintain data consistency between the model in the KB repository and the one in the BPM repository.
3.2
Project Management
SIMATIC IT Production Modeler is a modular product. The various modules making up the Production Modeler are organized as follows:
3.2.1
System files
The Production Modeler core and engine files are the actual system files. They are installed by default in folder identified by the value of the %ICUBEPATH% environment variable. The environment variable containing this information is %CUBEMESAD%.
3.2.2
Project files
Production Modeler allows users to manage PM plants data through projects. PM is essentially a multi-project core component where there is one PM server instance running for each project. The user creates and runs PM projects from the SIMATIC IT Management Console. When a PM project is started, PM server is also started up automatically with all required system files. All PM project information, such as plants and libraries data, is stored in a private format known as KB files or Knowledge Base. Normally, a PM project handles the following types of file:
Name
Description
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Name <project-name>.kb
Description Contains information about the user application: system parameters, user settings, plants and libraries. Contains the plants specific information (e.g. Plant Definition, Rules, ProductionOperations, External Links, Rules Execution Area.) Contains definitions for all user-defined objects (i.e. Plant Object Classes).
<plant-name>.pln.kb
<library-name>.lib.kb
These user files are stored in folder C:\UserKbs\USERKBS. In this folder the basic libraries kb files (.lib.kb) that the user needs in order to instantiate plant objects are also installed by default. The environment variable containing this information is %CUBEMESAD-USR%.
3.2.3
Version Files
Production Modeler documents, library and plant versions are stored by default in folder C:\UserKbs\DOC. The environment variable containing this information is %CUBEMESAD-DOC%. Each library or plant folder contains, by default, the following folders:
Contents All bitmaps specific to the library or plant. All documents specific to the library or plant. Each plant or library version saved in SIMATIC IT.
3.3
3.3.1
3-3
Table of Contents
3.3.2
Libraries Environment
Libraries environment is the place where the modeling phase of the Plant Library takes place. Here the user is able to manage the Plant Library based on the User Industry Libraries and the other system libraries provided by SIMATIC IT. Basically, the user is able to model the Enterprise (the higher level entity in the Equipment Hierarchy Model) in terms of libraries, classes, methods, events and rules.
3.3.3
Plants Environment
Plants environment is the place where the engineering phase takes place. Here the user instantiates the Production Modeler Plant (PM Plant) based on the Plant Library built during the modeling phase and manages the Equipment Hierarchy Model, deciding which objects compose the Plant Equipment. Plants environment allows also testing Plant Equipment activities by manual activation of rules.
3.3.4
Runtime Environment
Runtime environment is the place where the debugging phase takes place. From this environment the user is able to check the execution flow of elements which are activated directly from the Plants environment or from the external (i.e. from POM). This provides real time feedback on the systems behavior, with monitoring and real-time emergency analysis.
3.4
Basic Concepts
This chapter introduces some fundamental concepts related to Product Modeler.
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Table of Contents
3.4.1
Equipment Classes
Equipment Classes allows the user to create the Equipment Hierarchy Model as defined by ISA S95 standard. The Equipment Classes are directly provided by the system library named S95-Industry-Library and they are listed here: Enterprise (E) Site (S) Area (A) Cell (C) Unit (U)
3.4.2
3.4.3
Logical Classes
The Equipment Hierarchy Model can be extended with Logical Classes which can be dedicated to supply logical functions typical of software packages (e.g. scheduling management, reporting or printer functions). The Logical Classes are entered at the unit level and can be grouped to form logical cells. The logical classes are directly provided by the system library S95-Industry-Library and they are listed here: Logical-Cell Logical-Unit Production Modeler provides also two classes derived from the Logical-Unit dedicated to integrated custom applications; they are: GSI-Logical-Unit, provided in the GSI-INDUSTRY-LIBRARY Com-Logical-Unit, provided in the CUBE-COM-INDUSTRY-LIBRARY
3.4.4
Class Members
Each class in Production Modeler can be provided with a set of functionality supplied by: Methods: represent the various functions that the object can perform and which are of relevance to the application. Some examples are, add-material, agitate and empty-material for a mixer, start-heating for a furnace, etc. A method can have parameters describing the input and the output data. Events: correspond to an action that occurs within the object and to which the object must react in some ways, e.g., an error in a distillation-tank, a lack of raw-materials in one cell or, a detected delay discovered in on of the areas. An event can have parameters describing the input and the output data Attributes: correspond to different parameters related to the object, e.g., the maximum volume in a mixer, the current temperature in a furnace, the production-rate of a cell or the current workload in an area.
3.4.5
Equipment Rules
Each class can be provided with a set of Rules, grouped in apposite Rule Containers. A Rule is defined as a network of connected objects which establish the runtime execution logic through a path of intermediate steps. For a class, Rules represent the actions which can be performed by means of the available methods, events and attributes. At runtime, the path drives the execution engine through a series of actions according to the logical architecture of the rule.
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3.4.6
Plant
The Plant is the actual realization of the Enterprise as it is typically composed of the instances provided by the Equipment, Logical and Process Segment Classes. This means that a Plant contains: The Equipment Hierarchy Model instance (the actual model) The Process Segment instances used in the equipment The actual configuration of the equipment Rules and Attributes
3.4.7
3.5
3.5.1
Common-Tools
An User Industry Library has also the functionality of the objects provided by Common Tools, which allow the user to populate its library with dedicated sets of reusable objects each own performing specific tasks. The Common Tools container of a library is provided with the additional containers for the following types of objects: Custom Data Type and Data Builder Definition, useful to process each kind of data (text, float, structure, sequence) through an X-Path like language. Log File, to configure a set of CSV file objects to be used for logging purposes Custom Function, to define your own functions Life Cycle, to import custom life cycle from SIMATIC IT Production Order Manager.
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3.5.2
3.5.3
As from the diagram, a library version which is in Editing status can be modified in any moment. All changes inside the library itself are performable. When switching to the In-Production status, no modifications are allowed and commands are not available anymore. This status is particularly indicated when the library has been developed and it must be distributes to other users or customers. Note If your library is in In-Production status, you must create a new version of the library in order to switch back to the Editing status.
3.5.4
Adding Sub-Libraries
When working with a library, the user may need functionality provided by another library. In this case it is possible to add to the library a specified set of Sublibraries. This practice allows you to: create library classes based on the classes of a sub-library, inheriting all methods, events, properties and rules of the sub-library class override members such as rules, methods and events of the class sub-library use Common Tools objects provided by the sub-library
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Table of Contents For example, a user library must have the GSI-Industry-Library as Sub-Library in order to create GSI logical units. Normally the Plant Library contains various system and user libraries as sublibraries, in order to provide the plant with all required objects.
3.5.5
3.5.6
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Table of Contents Process Segment Classes: Process-Segment and On-Event-Segment. These classes are the actual production segments as defined by the ISA S95 standard. General Purpose Classes: Material-Production-Operation and Material-NonProduction-Operation.
3.5.7
3.5.8
3.5.9
Methods
As in object-oriented programming, a method refers to a subroutine that is exclusively associated either with a class or with an object. Methods are all the tasks which the class may perform with some dedicated rules. Usually a method consists of: The action to perform (the actions provided by the system or defined by the user) A set of input arguments to customize that action with specific values at runtime And possibly a set of return arguments which gives a response about the action or return some data Once a method is defined it can be invoked from a Rule by means of the MethodCaller step. This step allows reusing methods in the rules which at runtime can invoke the method simultaneously.
Events
The events shall be defined as all the messages (which may come from external or internal processes) to which the class must react with some dedicated rules. Events allow building event-based rules which are triggered automatically upon the event occurrence. Usually an event consists of: The message to wait for (the events provided by the system or defined by the user) A set of return arguments which gives a response about the event or return some data Once an event is defined it can be used from a Rule in two modes: By configuring the rule root to start upon the event detection By means of the Wait-For-Event step; this allows waiting the event occurrence after the execution of some intermediate steps in the rule.
Attributes
Each class can be configured with a set of user attributes which can be used for general purposes. PM provides attributes with various type values such as: Integers (INTEGER) Strings (TEXT) Floats (FLOAT) RTDS tags (CUBE-VARIABLE)
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Table of Contents Lists (SEQUENCE) User attributes have a general visibility within the library. This means that any rule from any class can manipulate these variables.
Rules
Rules implemented by a class take advantage of methods, events, attributes and other system objects exposed by the class, in order to coordinate them to fulfill a specific scope. The methods and events are then used in a Rule as building blocks in order to assemble a more advanced functionality. All rules exposed by a class determinate at runtime all actions which actually can be performed by that class and used in the production. A Rule typically consists of: A Root object, which gets the input arguments and redirects the rule return arguments An intermediate network of steps A set of End-Of-Rules, which terminate the rule execution and pass return arguments value to the Root object
3.5.10
3.5.11
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Table of Contents The process object (the Process-Object template property) determinates the scope of the process segment within the library. In other words, each process segment is related to a specific class for which it wants describe and direct the behavior. Normally, the process object corresponds to the equipment object related to that specific production step. For example, in the manufacturing of the chocolate the production step known as roasting is normally performed on big rotating ovens where cocoa seeds are roasted. From the point of view of your plant, a process segment can be defined for the roasting production step. The process object of this process segment could be any rotating oven Unit defined in your Plant Library. The process segment will make use of that unit functionality in order to accomplish the process of roasting. The segment resources define all the inputs required by the process segment in order to accomplish the production step as defined by the ISA S95 standard in relation with automated process segment (process segments without personnel resource). Segment resources which can be added to a process segments are: I/O Parameters (Input and Return Arguments) Material Specifications (Input and Return Mat Spec) Equipment Specifications (Equipment Spec) In particular from the S95-Industry-Library, two types of process segments are available: Process-Segment, useful in continuous manufacturing operations On-Event-Segment, useful in discrete manufacturing operations
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Table of Contents Init, for the control of all the initialization procedures Exe, for the control of the execution of the single operations End, for the control of the termination procedures Generally, each of these roots is connected to a logical network of steps which models the business flow of the process, driving the execution flow at runtime. Normally, the used steps may correspond to: A general purposes object provided by PM, such as the Xml-Data-Local-List or the Data-Builder. Script-Caller object, by which it is possible to call specific functions provided by PM. Normally, this step is used to access the segment resources for which ad-hoc functions are provided. Start-Segment object, by which it is possible to call other process segments. Method-Caller and Wait-For-Event objects, by which the exposed methods and events of the process-object can be invoked Pm-Event-Deduction object, by which the process object rules can be activated.
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Table of Contents For transition rules only, PM provide a specific object named Refuse-Transition. This object can be used within a transition rule as termination step to roll back a transition. It allows you to terminate the execution of a transition rule, and consequently the execution of the process segment as well, with the particular status 'Refused'.
3.6
3.6.1
3.6.2
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Table of Contents The population of the plant equipment is completely left to the user. In any moment new classes can be instantiated, choosing the base class from the S95Industry-Library, or from the plant library. About class members, in the Plants environment the user is able to modify rules and user attributes of the plant equipment instances without modifying the related plant library classes.
3.6.3
3.6.4
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3.6.5
3.6.6
Synchronizing Instances
During the engineering phase, it is allowed to switch back in the Libraries environment in order to apply some modifications to the libraries. In this case, in order to maintain library data modifications aligned with the plant, PM provides a synchronizing mechanism. Basically, synchronizing applies changes made upon the library classes to the related instances in the plants. If some rules have been modified directly from the Plants environment all changes will be lost reflecting the related library rule structure. Important Synchronization can be performed either in the Libraries or in the Plants environment. When synchronizing in the Libraries environment, all class instances are synchronized with their related class. On the other hand when synchronizing in the Plants environment, only one specific class instance at a time is synchronized with its related class Furthermore, PM provides a check about rules which have been added to the plant equipment directly from the Plants environment. Upon synchronization, even if these rules are not present in the library, they are not deleted to prevent to lose them. However this practice is not suggested and new rules should be added always in the library from the Libraries environment.
3.7
3.7.1
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3.7.2
3.7.3
3.7.4
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3.8
3-19
4.1
Software Architecture
The simplified architecture of the PDefM component is outlined in the following diagram:
As from the diagram, PDefM: PDefM Display represents the Presentation Tier PDefM Server (one of the Production Application Servers) represents the Business Logic Tier Components Database represents the Data Tier
PDefM exposes a GSI interface to interact with Production Modeler. In order to process product definition data coming from ERP systems PDefM is able to communicate with DIS through the B2MML connector.
The integration among the Production Application Servers is performed at database level.
4.2
Basic Concepts
This chapter introduces some fundamental concepts related to Product Definition Manager. In particular, the main engineering entities are defined and the logical relationships between them are illustrated as well.
4-1
Table of Contents
4.2.1
4.2.2
Product Segments
As defined in the ISA S95 standard, a Product Segment is defined as as the overlap of information between product production rules and the list of all resources required to produce a product. A Product Segment defines the parameters, materials and equipment resources in order to accomplish a specific production step. It addresses the basic manufacturing question: What resources must be used to perform this specific production operation? Product Segment is strictly related to production operations as it normally refers, identifies or corresponds to an available process segment defined in the production resource. Differently of the associated process segments, which are product independent, a Product Segment is related to a specific product.
4.2.3
4.3
Engineering Activities
The following sections try to summarize the most important engineering activities which can be performed by the Product Definition Manager functionality.
4.3.1
Table of Contents PPR can be defined as detailed data structure bringing product definition information: Plant name Final Material Life Cycle Version and Priority Custom Properties Product Segments
4-3
Table of Contents
4.3.2
As shown in the table each status is characterized by a combination of the two attributes which determines the characteristics of that specific status.
4-4
Table of Contents A PPR begins its STD life cycle in the ED status with the objective of reaching the AP status. During the ED and RA status the PPR can be modified, deleted but not used to create production orders. In these statuses, the PPR can also switch to the DEV life cycle if required. Once in the RA status it can change to the AP. When the PPR reaches the AP status it is not allowed any modification on it any more and production orders can be created from it. The status of a PPR cannot be changed to Approved if it contains a product segment reference to a PPR which is not Approved. Once in the AP status the PPR can change to the OB status. A PPR in this status is not editable and not active, and can not be used any more; it is maintained in the database for tracing purposes only. If the status change requires one or more electronic signatures, the status will not be changed until the electronic signatures have been attained.
4.3.3
Versioning of a PPR
PDefM manages PPRs through a simple versioning system which allows creating new PPRs from existing ones. The versioning mechanism is automatic and it is applied on the minor or major version of the PPR. When a PPR is created the first time, the first version of it is defined in the system (i.e. 1.00). Once a new version is created upon an existing one, the system increments automatically the minor or major version numbers of one unit according to the user conditions. For example, based on this first version (e.g: 1.00), a minor version can be created (e.g.: 1.01) or a major version (e.g.: 2.00). Generally, the new version of a PPR: Is based upon an existing version Has a new validity range in terms of time Generally, new versions are created in order to modify the configuration of a PPR which is not more editable (i.e. when it is in the AP or OB status).
4.3.4
4-5
Table of Contents When creating a Product Segment related to a Process Segment in PM, each equipment and material specification must be associated to those defined in the Process Segment. In this case, in the equipment specification the list of plant equipment for that particular specification must be indicated. If using MM, in the material specification the list of material definitions used by that particular specification must be indicated.The material definition will be assigned with its priority BOM, if defined, quantity, yield and scrap values. If using PRM, in the personnel specification the list of groups (with the required number of people) must be specified. Execution Equipment: used to list the equipment items which will be used by the assigned Process Segment. When creating a Product Segment related to a Process Segment in PM the equipment items corresponds to the process objects of the Process Segment. In this case, the equipment items should be specified according to the following rules: For not-parametric process segments one single process object should be indicated. For parametric process segments a class equipment or from one to many equipment instances. In this latter case, each equipment instance will have a priority. At the POM side, the Process Segment with higher priority will be used among those momentarily available in PM.
4.3.5
Health Checking
The Health Check operation is an optional operation which can be performed in order to check the consistency between data specified in the PPR and data present in the production resource information (BPM, MM, PDS-I, PRM repositories). Note that the two basic conditions are compulsory for the creation of production orders from a PPR: The PPR is in a status with the active attribute set to true (i.e. AP for STD or NA for DEV) The Health Check have been successfully performed Health check can be successively performed on PPR which are in Approved status, in order to check if data consistency with the other SIMATIC IT components is maintained in the PPR configuration along the time. For example, the Process Segment associated to one of the PPR Product Segment can be no more present in the BPM repository. In this case the Health Check fails signaling the inconsistency.
4.4
4-6
Table of Contents In particular, through the PDefM Display the interaction with production resource information as defined in the other components repository (BPM, PRM, MM) is made possible through the use of dedicate Explorer windows. Explorers are able to scan the SIMATIC IT production resource information with advanced queries and filters, minimizing operator input time and errors.
4.5
4.6
SIT_AddB2MMLDataStructure
SIT_GetB2MMLData
In particular, PDefM supports the following schema definitions: B2MML-V02-ProductDefinition.xsd (B2MML v2.0 for product definition) B2MML-V02-ProductDefinition_SITExtension.xsd (proprietary extension of B2MML v2.0 for PDefM)
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5.1
Software Architecture
The simplified architecture of the MM component is outlined in the following diagram:
As from the diagram, MM is based on a Multi-tier architecture (three-tier) where: MM Display represents the Presentation Tier MM Server (one of the Production Application Servers) represents the Business Logic Tier Components repository represents the Data Tier MM exposes also a GSI interface in order to interact with Production Modeler. The integration among the various Production Application Servers is performed at database level.
5.2
Basic Concepts
This chapter introduces some fundamental concepts related to the engineering and runtime entities which can be managed by Material Manager.
5.2.1
Material Model
The material model defines the actual materials, material definitions, and information about classes of material definitions.
5-1
Table of Contents Material Manager allows managing material resources in terms of a hierarchy model as defined by the ISA S95 standard. Additionally, other entities are introduced in order to fit better the user requirements: Material Type identifies a group of Material Classes all related to specific purposes in the production (e.g. raw materials, intermediate materials, subassemblies, parts, and consumables). From a Material Type zero or more Material Classes can be derived. Material Class is directly related to Material Type and it identifies a group of material definitions for use in production scheduling or processing (e.g. water -raw material). From Material Class it is possible to derive zero or more Material Definitions. Material Definition is a specialization derived from a Material Class (e.g. recycled water - raw material). It is a means to describe production goods with similar characteristics which can be used to make a product, but also to represent the product itself. From a Material Definition zero or more Lots can be defined. Material Definition. Material Lot uniquely identifies a specific amount (countable or weighable) of a specific Material Definition (e.g. 2 liters of recycled water - raw material).
5.2.2
Bill of Material
According to the ISA S95 standard, the bill of material is a list of all materials required to produce a product showing the quantity of each required. These may be raw materials, intermediate materials, subassemblies, parts, and consumables. Note that the bill of material includes material product-related but also materials not related to production, such as shipping materials. Bill of Material is always an alternative among a group of Bills of Material. This is because the material requirements to make a product may change and must be handled in a flexible way.
5.2.3
Location
Location is the determination of a storehouse for material lots. Locations can correspond directly to objects defined in the plant model (e.g. sites, areas, etc) or to private places not related to the plant equipment. Location allows the definition of places where materials can be moved into and from.
5.2.4
Handling Units
Handling Unit (HUT) is a means to describe a storage unit where lots can be allocated. HUT allows the definition of containers which can be charged and discharged with specific amounts of material.
5.2.5
Properties
Properties describe physical characteristics which can be associated to materials and handling units. Properties are typically dedicated to measure values according to a specific unit of measure provided by the International System of Units (SI).
5-2
Table of Contents Material Manager allows the assignment of properties to logical entities such as material classes, material definitions and handling unit types for modelling purposes. The values properties assume are specified at runtime in the related lot or HUT properties.
5.3
5.3.1
Engineering Activities
Defining the Material Model
The most important activity in MM is the definition of the material model. When defining the material model the user must create and configure entities according to the logical relationships established by the MM object model. This means that, basically, the material model must contain: 1. One Material Type 2. One Template Material Class based on that specific Material Type. 3. The first version of one Material Definition based on that specific Template Material Class. Since the material model can be as complex as required and the use of the MM entities depends strictly on the requirements of the SIMATIC IT application, the way the model must be defined is application-dependent.
5.3.2
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Table of Contents
5.3.3
By default, the Edit status is characterized by the Is Editable and Is Deletable attributes set to true. This means that a Material Definition which is in this status can undergo to modifications and can be deleted at any time. This status is particularly indicated for Material Definition versions which in a test phase. When a Material Definition is in Approved status it can not be modified or deleted and lots or sublots can be created from it. This status is typical of Material Definition versions which are ready to become part of the production resource. The only way such a version can be deleted is to switch to the Obsolete status. In addition, among those versions which are in Approved status, MM allows to flag one specific version as Current. This is particularly useful when the user wants elect a specific version as the currently used among the approved. In addition, it is possible to add a set of custom statuses. Each status can be configured only with the attributes provided by the system.
5.3.4
5.3.5
5-4
Table of Contents BOM alternatives in MM are managed by a simple mechanism of priority assignment. Each time a BOM is created, an integer is automatically assigned to it, defining the BOM priority within the set of existing BOMs. By default, MM assigns the priority 0 (i.e. higher priority) to the first created BOM, and afterwards each new BOM will have a priority increased by one unit. Obviously, the user is able to set in any time the BOM with the higher priority. A BOM is identified in the system by: its unique identifier and the related Material Definition version Each BOM is normally characterized by Its priority integer A quantity, defining the amount of material handled by the BOM related Unit of Measure (which must be compatible with the associated Material Definition version) Validity range in terms of time Properties with default values BOM Items, which determinate the materials required by the BOM itself
5.3.6
5.3.7
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Table of Contents Once Hut Types are defined they are identified in the system by a unique identifier by which the various Hut instances can be created at runtime.
5.3.8
Defining Locations
MM allows the definition and usage of locations as storage places for handling units and lots. Locations can be defined by: Importing Common Locations, which permits to import specific equipment actually stored in the BPM repository. Creating Private Locations. The available location types correspond to the basic equipment types specified in the ISA95 equipment model: Enterprise, Site, Area, Cell and Unit. Each location is identified in the system by: An identifier A location path, which locates the equipment within its hierarchy About Importing Common Locations, only the locations such as Enterprise, Site and Area can be referenced. Optionally their children can be imported too. About Private Locations, location hierarchies can be created by the user according to the S95 equipment model constraints.
5.3.9
Handling Properties
MM allows the creation of properties independently of the entity which will use them. This means that properties are considered as isolated objects which must be created and configured before be used for the association with MM entities. Additionally, properties can be grouped under property groups, which are userdefined. The basic information handled by a property specifies: Unit of Measure (UoM), for which all the most important UoMs defined in the global standard International System of units (SI) are available. Type Value, as variant, integers, floating points, strings, date time, decimals A general purpose description Some optional flag which indicate how the property will be used. Properties can be configured in order to be: Range, to specify range of values with lower and upper boundary Set, to specify a set of values Inheritable, which specify if the property can be inherited by lots and sublots when it is associated to a Material Class or a Material Definition A property can then be range and set, that is a set of range values can be specified for that property. Each new property is identified in the system by a unique identifier. After being defined, properties can be associated to the following entities: Material Class
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Table of Contents Material Definition, which automatically maps the properties of the related Material Class BOM BOM Item, which automatically maps the properties of the associated Material Definition Handling Unit Type Handling Unit, which automatically maps the properties of the related Handling Unit Type
5.4
5.4.1
Runtime Operations
Handling Lots
Once a Material Definition version is approved (i.e. its status is Approved), it becomes able to manage Lots and Sublots, which identify a specific physical amount of a material quantity. Normally, Lots handle the following basic information: Initial Quantity, the amount of material specified at the moment of the lot creation. Related unit of measure (normally inherited from the related Material Definition) Validity range in terms of time. Status Actual Quantity, the amount of material currently available In addition lots can be assigned to locations, by specifying an existing location path among the available Common or Private Locations. Each Lot is identified in the system by: Its unique identifier And the related Material Definition version Once a lot is created, it can be used as a physical representative amount of that specific Material Definition version and it is possible to use it to perform genealogy operations.
5.4.2
5-7
By default, MM sets all attributes to true except for the Blocked status where the Is Operable attribute is set to false. This means that a Lot which is in Blocked status, it appears as locked and no operations can be performed on it: lot can not be moved, joined, disassembled, transformed, etc. The user can modify the default configuration of each status and eventually add other statuses to the system life cycle.
5.4.3
For example, assume to manage a certain material by 1 Kg/Lot. This means that the initial quantity of each lot is normally 1 Kg. If during a certain operation you consume the 50% of a lot, the actual quantity of that lot is halved and in the next operations you have still the 0.5 Kg of that lot to consume. In addition, you can supply 0.5 Kg to that lot in order to restore the quantity to 1 Kg.
5.4.4
5-8
Table of Contents
As to genealogy operations, each lot handles the following basic fields in its history: Operation Date, date and time when the operation has been performed Source Identifier, the source lot in the operation Target Identifier, the target lot in the operation Associate To, a custom string configurable before performing the operation; this string is generally used to indicate the cause of the operation Comments, additional remarks The available operations can be summarized as follows:
Operation Split Join Transform Assemble Purpose Splits a specific amount of material into another amount of material. Joins two or more lots to form a single lot Transforms a lot into another lot Assembles two or more lots into other lots
MM automatically checks and processes lot quantities as they undergo to the various operations. Important These operations can be performed only on lots whose status has the Operable attribute set to true (i.e. the status is not Blocked).
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Splitting Lots
Split operation separates a source lot into n parts of a specific quantity. In this kind of operation, lots pertain to the same material definition. The user must specify the source lot to split and the target lots to generate by the split. Assume you want to split a lot into two parts. The split can be made upon: The entire quantity; this will divide the lot in two. A custom quantity; this will generate a lot of the specified quantity. The following diagram shows a split made upon the entire quantity (Q=n), in a simple use case:
The source lot whose quantity was Q=n, after the split, its quantity has been halved to n/2 and a new lot amounting to n/2 has been generated. The following diagram shows a split made upon a custom quantity (q=m):
In this case, the user has specified a custom quantity of m. After the split, a new lot which amounts to m has been generated and the original lot now amounts to n m. The Lot generated in the split operation, has the same characteristics of the old one. Optionally the user can specify if property values can be inherited from the related material definition or the source lot, and if the source lot must be deleted after the split.
Joining lots
Join operation causes a list of lots related to the same material to become joined in a target lot. It can be seen as the opposite of the split operation. In this kind of operation, lots must pertain to the same material definition. The following diagram shows the situation before the join, in a simple use case:
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The user specifies the source lots (Lot 1 and Lot 2) and the target lot (Lot 1). After being performed the operation, the source lots are removed as they become part of the target lot and the amount of the target lot becomes the sum of the source lots amount (Q=n+m):
Transform
Transform operation converts a list of source lots (also lots related to distinct materials) into a list of target lots. In this kind of operation, lots can pertain to distinct material definitions. During a transform operation a specified amount (or the entire amount) of the source lots is consumed and consequently it is produced the specified amount of the target lots. The following diagram shows the situation before the transformation, in a simple use case:
The target lot (Lot D) has an actual quantity (Q=z) and a target quantity (q=x). It must be generated from the source lots (Lot A and Lot B). After the transformation, source lots quantity becomes zero and Lot D actual quantity assumes the target quantity (Q=q=x):
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Assemble/Disassemble
Assemble operation produces a lot putting two or more lots together. In this kind of operation, lots can pertain to distinct material definitions. A lot which has been assembled can be successively disassembled taking apart its constituent pieces. The user must specify the source lots and the target lot into which source must be assembled. The following diagram shows the situation before assembling, in a simple use case:
Source lots (Lot A, Lot B, Lot C) must assemble Lot D which has an initial quantity (Qc=t). After being assembled, the source lots are removed and the assembled lot amounts to the same initial quantity (Qc=t), but now, it is composed of distinct lots amounting to a certain quantity.
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Table of Contents The assembled lot can be successively disassembled taking apart Lot A, Lot B and Lot C.
5.4.5
5.4.6
Charging/Discharging Huts
When an handling unit is created it is possible to charge it with a set of lots. In turn, a charged Hut can be discharged of its lots. A charge/discharge operation always traced in the Lot/HUT History with their Associate To string and Comments fields. As to charge/discharge operations, each lot handles the following basic fields in its history: Old Hut ID, the handling unit from which the lot has been discharged New Hut ID, the Hut into which the lot has been charged
5.4.7
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Table of Contents Free Locked Occupied Reserved The available attributes for each status are:
Attribute Is Editable Is Deletable Description The hut can be modified. The hut can be deleted.
By default, MM sets all attributes to true except for the Locked status where both attributes are set to false. This means that a Hut which is in Locked status can not be modified or deleted. The user can modify the default configuration of each status attribute and eventually add other statuses to the system life cycle.
5.4.8
Moving Operation
When a Lot or a HUT is assigned to an existing Common or Private location it can be moved from it into another location. Normally, when a lot is charged into an handling unit MM keeps automatically trace of the movement of the lot from one location to another as the handling unit containing it is moved. A move operation is always traced in the Lot/HUT History with their Associate To and Comments fields. As to move operations, each lot handles the following basic fields in its history: Operation Date, date and time Old Location Path, the location path from which the lot has been moved New Location Path, the location path into which the lot has been placed
5.4.9
5.4.10
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5.4.11
5.5
Using MM Display
Material Manager is provided with a user-friendly graphical interface, the MM Display, which allows the user to take advantage of the functionality and perform manually all the engineering and runtime activities described in the previous sections.
5.6
5.7
The input argument is provided through an XML string which indicates: The path of the data files containing the configuration about the entities to import Various filter conditions for the exclusion of some records specified in the data files. The filter condition is provided as in a Where SQL clause Various replace instructions for the change in the configuration of specific data The various properties to import specified by their ID Working modes Options
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Table of Contents In addition to the XML input string, the user must provide the data files (.dat) which store the information about the potential data which can be imported and a format file (.fmt) which specifies the format of the data using the same standard notation of BULK Insert operations of Transact-SQL. The following objects can be managed: Property Material Type Material Class Material Definition BOM BOM Item Each object is specified in the data file as a single record and each record must contain some basic information such as the object type and the object identifier: Additionally, it is possible to specify hierarchy of data relating an object ID to its father object ID. The allowed associations are those allowed by the logical relationships among the Material Manager entities: Properties with Property Groups Material Classes with Material Types Material Definitions with Material Classes BOMs with Material Definitions BOM Items with BOMs
5.7.1
In particular, MM supports B2MML v2.0 schema definition (B2MML-V02Material.xsd) and it is provided also with a proprietary schema (B2MML-V02Material_SITExtension.xsd) which allows the extension of the standard B2MML with MM entities.
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Table of Contents Details about the XML data schema are provided in the Material Manager documentation.
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6.1
Software Architecture
The simplified architecture of the POM component is outlined in the following diagram:
As seen in the diagram, POM is based on a Multi-tier architecture (three-tier) in which: POM Display represents the Presentation Tier POM Server (one of the Production Application Servers) represents the Business Logic Tier The Components repository represents the Data Tier POM also exposes a GSI interface for interaction with Production Modeler. The integration among the Production Application Servers is performed at database level.
6.2
Basic Concepts
This chapter introduces some fundamental concepts related to the engineering and runtime entities which can be managed by Production Order Manager.
6.2.1
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Table of Contents Orders, which identify a specific production request made up of a subset of segment requirements. Entries, which identify a specific segment requirement to support production activities. The hierarchy model can be summarized as follows: 1. The father entity in the hierarchy is the Campaign. 2. A Campaign, in turn, groups the set of production requests identified as Orders. Orders can not be defined apart of a Campaign and a specific Order can belong only to one Campaign at a time (by default, POM groups Orders under the system Campaign named Default). 3. An Order, in turn, is made up of a set of segment requirements identified as Entries which can not be defined apart of an Order.
6.2.2
Time Frames
A time frame in POM is a means which allows defining identifiable time intervals in terms of days, months or years. Time frame can be used during the planning phase of the production requests to set the validity of a request in terms of time. During the configuration of a Campaign the validity is set to a specific Time Frame which limits the range of the Campaign Estimated Start and End Time (and also of the Campaign Actual Start and End Time). Orders too can be associated to a Time frame, which limits the validity range of the associated Order Estimated Start and End Time (and also of the Order Actual Start and End Time).
6.2.3
6.2.4
Life Cycles
Each Campaign/Order/Entry can be associated to a Life Cycle, which is a set of: All the possible Statuses of an entity (e.g. "Initial", "To Be Scheduled", "Scheduled", "In Progress", etc). Status Transitions, indicating the possible state changes (e.g. from status "Initial" to status "To Be Scheduled")
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Table of Contents Each Status has Attributes which can be used to specify the actions which can be performed on the entity which is in that status. For example, an Entry can be deleted only if its status has the "Can Be Deleted" attribute.
POM provides three Standard Life Cycles, named "System", for Campaigns, Orders and Entries. The state machine defined by the Standard Life Cycle contains all the status definitions with the required attributes in order to manage correctly POM entities status transitions. Additionally, it is possible to implement Custom Life Cycles, Custom Statuses and Custom Attributes to fit better the application purposes. A Custom Life Cycle can use both System Statuses and Custom Statuses, and a Custom Status can use both System and Custom Attributes. A special set of System Attributes, named "aliases" (or "synonyms") which can be used relate a Custom Status to an equivalent System Status.
When a Campaign/Order/Entry is created, it is associated to a Life Cycle (the "System" Life Cycle is used by default) and to a Status (the "Initial" status of the "System" Life Cycle is used by default) but those associations can be modified at any time.
6.2.5
Custom Properties
POM allows the creation of custom Properties as single entities and then the free association of those Properties to various entities (Orders, Entries, Execution Equipments, Material Specifications and Material Specifications items, Equipment Specifications and Equipment Specifications items). According to the information intended to supply, a Property may represent numerical, textual and date time data and can be configured in various way depending on the specific purpose. Custom Properties may be implemented in order to: Provide entities with specific values at runtime concerning any useful data which is product-related or not. Undertake decisions at runtime on the base of specific values. Distinguish entities on the base of some assumed values. Triggering detectable events on the base of some assumed values. Manage quantities with multiple values and tolerance ranges.
6.3
Engineering Activities
This chapter provides a general but comprehensive overview of all the possible engineering operations which may be performed by an application using POM.
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Table of Contents In any case, their use is helpful because allows the user in defining the required set of time range and reuse them in any moment during the creation/update of an Order. Time Frames must be created before their association to Campaigns and Orders. Once a Time Frame is created, it is identified in the system by its unique identifier which can be used during the creation of the Campaign/Order to make the required association.
6.3.2
6.3.3
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Table of Contents The user may want to create a custom status - named e.g. "Finished" - which has the synonym-attribute "Is Completed" to specify that the custom status is similar to the system status "Completed" One or more Attributes of type Action which determinate the actions executable on the Status it self. For example, the Status "Completed" has the action-attribute "Can Be Archived" (a Completed entity can be sent to historical tables), but it does not have the action-attribute "Can Be Deleted" (a Completed entity cannot be deleted). The user may want to create a custom status - named e.g. "Finished" - which has different attributes, so that different actions are allowed or denied on an entity in that status. Finally, life cycles are characterized by transitions which specify the possible changes from one status to another. A transition is generally defined by: The starting status of the transition (known as "Status From", or "Current Status"), The target status of the transition (known as "Status To", or "Next Status"),, an associated Transition Attribute: in fact, more than one "parallel" transitions may be defined between the same statuses, and the Transition Attribute is used to distinguish them. The Transition Attribute is also used by some special POM GSI SIT methods (the ones which name contains the "SetNext" clause) to change the status of an entity without knowning the exact name of the next status (Note that, conventionally, if an attribute is used as Transition Attribute for a transition, it is also associated to the starting status, but this is not mandatory: for example, since the System Life Cycle for Entries has a transition which connects "Initial" and "To Be Scheduled" via the "Can Be To Be Scheduled" transition attribute, then the "Initial" status is also associated to the "Can Be To Be Scheduled" attribute. But if the user defines a custom transition between status X and Y via transition attribute A, it is not needed to associate attribute A to status X).
Important When the defining a Custom Life Cycle for Entries related to On Event Process Segments, be sure to include at least the following: - One status with the attribute Is Initial, where this status is the only one with this attribute in the life cycle's set - At least one status transition
Once created, a Custom Life Cycle is identified in the system by its unique identifier which can be used during the creation of the Campaign/Order/Entry to make the required association.
6.3.4
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Table of Contents Manage list of values (Multi Value option) Be associated to more than one group (Multi Group option) Additionally, each property can be configured with constraints which limit the values acceptable by the property itself. The constraint can be: Constant, if the property can only assume a specific value Set, if the property can assume only some specific values Range (only for numerical properties), if the value the property must assume can accept a certain margin of tolerance. Note: if a runtime value associated to a Property violates a constraint, a warning is generated. Once a Custom Property is defined in the configuration table, it is referenced inside the system by its unique identifier and type, by which it may be associated to any entity. Once defined properties can be associated to entities during the creation of the entitiesitself but their association can be modified in any moment. At runtime, properties associated to entities assume values which can be used for general purposes, like data processing, information tracking, or decision-making processes.
6.3.5
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ScaleFactor = OrderQuantity
BatchDefaultSize
As from the formula, if OrderQuantity is equal to the PPRBAtchDefaultSize the scale factor corresponds to the unit (1) and Entry values will be the same of the corresponding Product Segment values. Differently, if OrderQuantity is half of the PPRBAtchDefaultSize the scale factor corresponds to 0.5 and Entry values will be halved (a part of the material quantities with flag Quantity Relative that represent a percentage of the BOM reference quantity). After the Order is created it can be fully modified. This means, for instance, that at runtime, upon the order instantiation, previous of its dispatching, it is possible to change on which piece of equipment each entry must be executed which alternatives inside the specifications must be used and so on.
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Table of Contents The dispatch of such an Entry has the consequence of starting the Process Segment in Production Modeler, thereby starting the related Rule of Rules. At the dispatch, Entry data is passed to the Process Segment: Input Parameters Value (passed to the Rule of Rules Input Arguments) Material Specifications Equipment Specifications As the Process Segment execution ends, values in POM are actualized and Material values are sent back to POM in the Actual fields of the Entry Material Specification items.
6.4
Runtime Operations
This chapter provides a general but comprehensive overview of all the runtime operations which generally may be performed on the engineered POM entities.
6.4.1
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Table of Contents Quantities can only be set from Production Modeler, through a rule using the available POM GSI SIT Methods such as SIT_SetOrderQuantityList and SIT_SetEntryQuantityList.
6.4.2
Splitting Entries
At runtime, it is possible to split all the Entries which are in a status with Can Be Split attribute. About system life cycle, this means that the Entry must be in the Initial, To Be Defined or To Be Scheduled status. The split of an Entry produces a set of batches (Sub-Entries). By default, all the Sub-Entries produced during the split are scaled in proportion to the number of split entries. For example, if an entry is split in two identical batches, each SubEntry quantity will be halved.
6.4.3
6.4.4
6.4.5
Archiving Data
POM provides the users with the possibility of archiving data related to Orders dispatched at a specific time. To archive an order related to the specified entry ID, all entries (including the Background PO or Job associated to the Order) must be in a status with the attribute Can Be Archived. Data archives can be created about specific periods and backup can be saved on remote hosts.
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6.6
6.7
a POM GSI System Method Caller configured to call the SIT_ AddOrChangeCampaignTree with the input SIT_CAMPAIGN provided by the Data Builder step. The use of this method is very useful to manage data one-shot and with a very short variety of rules (may be just one as in the previous example).
6.8
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Table of Contents The strategy of importing data from an ERP system is various and may change according to the application requirement. Generally, POM provides a set of methods in order to manage such process from Production Modeler rules:
Method SIT_AddB2MMLDataStructure Purpose Creates or replaces data in the POM repository according to a SIT structure B2MML-like Creates data in the POM repository according to a B2MML string Deletes data in the POM repository according to a B2MML string Updates data in the POM repository according to a B2MML string Retrieves data from the POM repository according to a B2MML string
In particular, POM supports B2MML v2.0 schema definition and it is provided also with a private schema named B2MML-V02ProductionSchedule_SITExtension_V02.xsd which allows the extension of the standard B2MML with POM entities. Details about the XML data schema are provided in the Production Order Manager documentation. In addition, it is important to ensure that the resulting data structure meets all requirements regarding Product Segment data structure for scheduling, and for this purpose POM gives all the flexibility to configure the Order Entries to which Product Segment are to be related.
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7.1
Personnel Management
People represent one essential resource in the manufacturing system. They must be configured in the MES system, together with their characteristics, such as the skill of each person or of a group of people. The System must allow the assignment of shifts to people, and be aware and log each person's detailed activities during their working shift. Besides this, an MES System must also allow the integration of personnel data and production data: for example to check the personnel required for a task, or to log on which equipment, material lot, batch or order each person worked. SIMATIC IT Personnel Manager (PRM) handles personnel management within SIMATIC IT Production Suite.
7.2
Feature Highlight
The following information is an overview of SIMATIC IT Personnel Manager features: Configure Groups of People. Personnel single definitions can be grouped in order to have homogeneous management for a pre-defined set of people. Configure Properties for Groups. Properties can be defined at the Group level so that all people belonging to the Group inherit them. Configure Individuals. Single person profiles can be configured to have, when necessary, specific properties associated to the person themselves. Create Work Schedule Rules and Work Schedules Easily and Flexibly: Configure shifts, which are the basic building blocks for Work Schedules Configure periods (for instance a standard week) combining shifts and Holidays Configure rules to create Working Schedules (for example, one rule consists in the repetition of one period) Create Working Schedules
Importing and Exporting to/from ERP. All the data mentioned above may be imported or downloaded automatically from an ERP. Creation and Assignment of Work Schedules. Work schedules can be defined and then assigned to people or group(s). Association between Individuals and one or more SIMATIC IT User. Persons defined inside SIMATIC IT Personnel Manager might be associated to one or more user log-ins. Configure Personnel Constraints on Production tasks. It is possible to configure the number and properties of operators required to perform a step of a Production Operation. The Production Operation will also allow
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Table of Contents configuration of the actions that must be done at runtime, whether the constraint is satisfied or not. Data Collection. Collect each persons actual Working times, including the breaks. The component-based approach used by SIMATIC IT Framework allows integration of Personnel Managers with the System used in the Plant to collect the data about Personnel working times. Constraint Checking. For any Production Operation step on which the personnel constraint was configured, at runtime such constraint is checked. If the people configured for such step are not currently available, the Production Operation will take the appropriate actions as configured (E.g. send e-mails, or other messages to Operators, abort the current Order, to create a report). Specific Data Logging. Together with the Working times of each person, other Personnel Log data may be stored: the Equipment where the person was working the Production Order ID, or the Batch ID the material lot or sublot which the person is working on changes in the value of any Property associated to the person
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8.1
Overview
The Shift Calendar (SHC) component is able to manage calendar and working shift information that can then be shared among other SIMATIC IT Components. The basic functionalities of the SHC module are the management of a factory calendar, working time models (shifts) and calendar exceptions. The responsibility for defining associations between resulting calendars and calendar exceptions is maintained within each module managing such resources Consumers of SHC services are the PRM for the personnel resources, PM/BPM, PDS and PPA/DTM for equipment resources. Association between personnel and calendars is managed by PRM. Association between equipment and calendars is defined inside PM/BPM and then used by PDS and DTM. An association ID uniquely provided by SHC is used to keep track on other modules of the calendar entities associated with each resource instance. Calendar entities need not to be versioned or approved and once associated with a resource instance they are automatically linked with the current instance of such resource. The SHC server can be used to manage calendar information in an independent way, without the presence of all SIMATIC IT components, thus supporting the requirements for Lite bundle configurations as the OEE/DTM-Lite.
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9.1
Overview
The primary purpose of SIMATIC IT Data Integration Service (DIS) is to enable the integration of the MES layer (level 3) with the Business layer (level 4). Data integration is made possible by means of XML message exchange through asynchronous and synchronous operations. Furthermore, DIS ensures compliancy with standard and proprietary formats enabling data import/export in SIMATIC IT by means of XML messages coded according to specific schema definitions (e.g. B2MML).
9.2
Software Architecture
The following diagram shows the simplified architecture of DIS:
As from the diagram, DIS: Communicates with external systems by means of specific connectors. Communicates with Production Modeler through the PM GSI Connector. Communicates with SIMATIC IT S95 components through the B2MML connector.
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Table of Contents Is provided with a Runtime Console in order to monitor project active connectors and threads at runtime. Is provided with a Management Console in order to configure the various projects in the engineering phase. Manages runtime data by means of a specific project database. Archives old data into a dedicated Backup Database.
9.3
Connector Support
The following table lists the various connectors provided by DIS, describing their purpose as well:
Connector PM Purpose Message routing with Production Modeler. Two connectors are available: B2MML PM COM Interface Connector (retained for compatibility) PM GSI Interface Connector (recommended)
Message routing with SIMATIC IT S95 components: Product Definition Manager (PDefM) Personnel Manger (PRM) Material Manager (MM) Production Order Manager (POM)
SAP
Message routing with SAP systems with the following formats: IDoc tRFC sRFC
For reading/writing system files Communication with IBM Websphere Queuing System Communication with Microsoft Message Queuing System Communication with third party application which supports COM technology Allow applications to send requests to remote web servers and applications and provide or retrieve data with the ease of the DIS messaging-based communication system. Allow third party applications to connect to databases, execute stored procedures, functions and queries and read data Allows third party applications to exchange XML and text messages with SIMATIC IT DIS and other connectors Communication with custom .NET applications (either Windows or Web based applications)
ADO
Web Service
.NET
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10.1
10.1.1
Software Architecture
CAB Environments
SIMATIC IT Client Application Builder (CAB) is a platform dedicated to the development of graphical user interfaces focused on displaying SIMATIC IT data. It consists of two environments: The engineering environment (CAB engineering): where GUIs are developed from within the Microsoft Visual Studio .NET through CAB components. GUIs are structured as WEB applications (CAB web pages), being ASP. NET the CAB underlaying technology. The runtime environment: where CAB applications are executed as requested by remote clients.
10.1.2
10.1.3
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Table of Contents
As from the diagram: The client (relying on Microsoft Internet Explorer) displays Cab pages to the end user and sends requests either to CAB Server or CAB Web Server. CAB Server manages data in the connected scenario and it is also provided with specific objects allowing direct communication with Production Modeler and Real Time Data Server. Access to components is performed thorugh Production Modeler. CAB Web Server (relying on Microsoft Internet Information Services) executes CAB applications as by requests coming from clients. It handles data exchange in the disconneted scenario and communicates with Production Modeler (rule execution) and Real Time Data Server (spot reading). Components data retrieval is also made possible thorugh Smart Query Builder (SQB). Communication with CAB Server sometime is required.
10.1.4
CAB Portal
As of SIMATIC IT 6.3 SP1 the CAB Portal is released CAB Portal as an evolution of SIMATIC IT CAB, designed to reduce effort and time in creation of web-based client pages and projects. Easy and quick application development
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10.2
10.2.1
Data Access
As explained in the software architecture (see 10.1) data access is managed following two distinct approaches. These approaches take advantage of specific CAB objects: In a connected solution data is mainly managed using specific CAB data sources which are bound to specific CAB items, but also wide set of ActiveX controls are available. In a disconnected solution data is mainly retrieved via SQB using the SQBDataSource object and data access is performed executing rules on Production Modeler. Various classes and tools are available in order to guarantee data access and interaction with the various SIMATIC IT components (e.g. PPA, MSM, MM, RTDS, etc.).
10.2.2
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10.2.3
Security
A specific library (SITCAB.Security) is dedicated to manage user access security to CAB web pages. The two main concepts in security (authentication and authorization) are handled by two dedicated modules: Authentication (for user recoginition and validation) is handled thorugh the CABAuthenticationModule class. Interaction with the authentication system is obtained by specific methods which allow the management of login, redirection and sign out process. Authorization (for user resource rights and page visibility) is handled thorugh the CABAuthorizationModule class. The purpose of this module is to ensure that a user who has already passed the authentication procedure, has an access level high enough for the requested page (or a part of it). If the access level is lower than the required one, the user is automatically redirected to the error page. Users are created and assigned to groups in the User Manager environment. User authentication relies on SIMATIC IT User Manager and thus CAB retains the same user rights and permission configurations as applied in the User Mangement environment. Before using these two modules a system configuration is required by configuring the dedicated file web.config. This file allows declaring the modules and configuring some basic security parameters.
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SIMATIC IT Historian
11.1
Overview
The Historian component allows the efficient archiving of huge amounts of historical data collected from the active plant. Such data are stored on a preconfigured set of Online Databases that are cyclically managed in order to limit the total size of each online database. Each time the total amount of online data exceeds a preconfigured threshold, one or more online databases is put offline and becomes part of the historical data set. A separate Config Database contains the information and metadata about the historical data gathered from the plant.
11.2
Data elaboration by means of pre-defined functions and VBScript custom code: Pre-validation functions Post-validation functions Pre-defined statistical functions
Table of Contents On data change On Event Cyclically (on time) KPI results Out of bound results
Event notification:
The PPA component is responsible for managing EBR (Electronic Batch Recorder) functionality when associated to SIMATIC Batch by means of a specific programmatic interface. PPA can be also configured in order to store WinCC messages in custom data structure defined by the user in order to organize the archived data in an easy-touse way.
PPA sub-components
PPA also supports the integration with PCS7/Simatic Batch: these are not products part of SIMATIC IT but within the Siemens A&D product portfolio a direct integration path is provided towards the SIMATIC IT environment. Functionalities include: EBR functionality makes PPA able to archive all procedure elements of a batch execution WinCC messages collection makes possible to configure custom specific data filters in order to collect messages provided by WinCC system and are store them in dedicated custom tables to allow further processing of these raw data. Another task of PPA when integrated with Batch is the archiving of Batch related AT/ESIG (Audit Trail / Electronic Signature) information into CS database.
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HDD sub-components
The Active-x objects currently available are the following: HDDX displays archived data in trend format offering different display option in order to allow trends comparison. BgViewer displays archived data in bar graph format. Production Viewer displays production data contextualized with corresponding Batch data or Production Key data. The batch data are retrieved from the EBR (Electronic Batch Recording) archive. Message Viewer displays archived Message data optionally contextualized with corresponding Batch data
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