PROJECT FINAL REPORT - European Commission ...cordis.europa.eu/docs/projects/cnect/8/260018/080/...Cooperation Collaborative project (IP) 260018 PLANTCockpit FP7-2010-NMP-ICT- FoF

Cooperation Collaborative project (IP)

260018 PLANTCockpit FP7-2010-NMP-ICT-FoF (Information and Communication Technologies)

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PROJECT FINAL REPORT

Version: 03.06.2014

Grant Agreement number: 260018

Project acronym: PLANTCOCKPIT

Project title: Production Logistics and Sustainability Cockpit

Funding Scheme: CP-IP

Period covered: from 2010-09-01 to 2013-12-31

Name of the scientific representative of the project's co-ordinator, Title and Organisation:

Dr. Volodymyr Vasyutynskyy (SAP)

Tel: +49 351 4811-6159

Fax:

E-mail: [email protected]

Project website address: http://www.plantcockpit.eu/



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Contents

1. Final publishable summary report 3

1.1. Executive summary 3

1.2. Beneficiaries of the project 4

1.3. Project context and objectives 5

1.4. Main S&T results and their impact 8

1.5. Matching of objectives and results 21

2. Use and dissemination of foreground 23

2.1. Report on societal implications Error! Bookmark not defined.

3. Final report on the distribution of the European Union Financial Contribution Error! Bookmark not defined.



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1. Final publishable summary report

1.1. Executive summary This document comprises the final report for the ICT FP7-260018 Integrated Project PLANTCockpit “Production Logistics and Sustainability Cockpit”.

PLANTCockpit offers manufacturing communities a central environment for monitoring and controlling of production and intra-logistical processes. PLANTCockpit gives production supervisors, foremen, and line managers the required visibility to make well-informed decisions for optimising plant processes. This includes the holistic visibility of the plan, the current status, deviations and exceptions, and bottlenecks. PLANTCockpit provides a model for integrating heterogeneous shop floor management systems including ERP, MES, SCADA, condition-based maintenance, energy management and other special-purpose systems. The project conducted a comprehensible assessment and analysis of current business processes and requirements on such systems with the help of the specially developed methodology, allowing extracting the most common needs from different industrial areas along with domain-specific demands.

The provided solution comprises a generic layered architecture based on service oriented principles, which combines the openness and flexibility with easy adjustment to the specific use cases. The architecture exploits the concept of reusable Function Blocks, which are the platform components realizing the business logic and the configurable Function Block networks are realizing the concrete application scenarios. The reference implementation of the architecture has been provided in the PLANTCockpit integrated platform based on the open platform of Apache Service Mix. The project implemented the generic functionality supporting configuration of the platform and Function Blocks, eventing and messaging interfaces between Function Blocks, routing and security mechanisms for communication between Function Blocks, components for access and data integration from heterogeneous data sources, data modelling and persistence, and generic components for analytics and visualization etc.

For specific use cases of the industry partners of PLANTCockpit, the corresponding prototypes have been realized by configuration of the Function Blocks and implementing their specific functionality, demonstrating the practical applicability of the platform in such industrial areas as foods and beverages, automotive, building construction and semiconductor manufacturing. The prototypes addressed such relevant industrial aspects as KPI analysis, energy optimization, material tracking, and asset utilization, thus achieving the direct industrial impact.

Based on the integrated platform and identified, PLANTCockpit developed advanced concepts and technologies for areas of data visualization on desktop and mobile devices using .Net and HTML5 technologies, concepts for user perception support during the data analysis, concepts for easier configuration of access and integration of data from different data sources using semantic technologies, as well as for analysis of KPIs.



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The practical benefits of the prospective users of the platform and concepts include a quicker setup of the platform due to uniform configuration mechanisms, better visibility of the processes due to tight integration of different systems and data presentation on different devices, as well as more precise and quick decision making due to advanced analytics.

The further focus of the project lies in the practical exploitation of the achieved research results. The developed concepts and components have been successfully transferred into five existing and new software products of the project partners. The core components of the platform combined in the Function Engine will be further developed as an open source solution, see http://www.tut.fi/plantcockpit-os. The integrated demonstrator has incorporated the prototypes of use case partners (Acciona, BMW, Comau, Doehler, Intel), demonstrating the different aspects of the solution, among other at living labs of project partners. The industrial and academic impact has been achieved by a plenty of publications, presentations, industrial and standardization bodies, industrial fair booths and direct contacts with prospective users. The project also intensively participated at European coordination activities and workshops, actively shaping the future European research agenda in the area of manufacturing and ICT.

The project started in September 2010 and concluded in December 2013. Presentations, fact sheet, technical reports and further information can be found on the project website: http://www.plantcockpit.eu.

1.2. Beneficiaries of the project The beneficiaries of the project and their contact data are presented in the table below. Please avoid publishing the contact details on persons to avoid spamming.

No Name Short name Country Contact person

1 SAP AG (Coordinator) SAP Germany Volodymyr Vasyutynskyy [email protected]

2 Acciona S.A. ACCIONA Spain Christian Baraja Cuadrado [email protected]

3 BMW AG BMW Germany Christian Gruebel [email protected]

4 COMAU S.p.A. COMAU Italy Fulvio Rusina [email protected]

5 Doehler Group DOEHLER Netherlands Ralf Boywitt [email protected]

6 Ecole Polytechnique Fédérale de Lausanne EPFL Switzerland Dimitris Kiritsis

[email protected]

7 Fundación Tecnalia Research & Innovation TECNALIA Spain Jon Agirre Ibarbia

[email protected]

8 Iconics Inc. ICONICS Netherlands Vojtech Kresl [email protected]

9 Intel Corporation INTEL Ireland Jessica C. Mccarthy



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[email protected]

10 Politecnico di Milano POLIMI Italy Marco Taisch [email protected]

11 Technische Universitaet Dresden TUD Germany Martin Wollschlaeger

[email protected]

12 Tampere University of Technology TUT Finland

Jose Martinez Lastra [email protected]

13 Platte Consult GmbH PC Germany Klaus-Dieter Platte [email protected]

1.3. Project context and objectives Today, numerous methods, systems, and tools exist to facilitate production management, optimize resource utilization, and process efficiency. However, current ERP (Enterprise Resource Planning) systems, MES (Manufacturing Execution Systems), SCADA, and special-purpose solutions are rarely integrated with each other and typically provide no more than point-to-point interfaces between selected functionalities. These sporadic point-to-point integrations do not fulfil the requirements of today’s dynamic markets where enterprises have to quickly judge complex situations, react to unexpected events, and make far-reaching decisions.

With the growing focus on sustainability, complexity grows even further as production supervisors have to manage energy and material consumption, carbon footprint, and waste output in addition to classical Key Performance Indicators (KPIs) like process efficiency, asset utilization, quality, scrap rate, and costs. Efforts to find the optimum for yield, quality, speed, or energy consumption individually often result in local optima, far from the ideal solution. Optimization must start at global bottlenecks within the plant or supply network, which can only be identified if overall process transparency is given. Only a tight integration of all systems will provide the visibility and process integration needed to truly recognize the potentials and optimize intra-logistics processes – be it with respect to yield, quality, energy consumption, or waste.

The vision of PLANTCockpit is to offer to manufacturing communities the central environment for monitoring and control of all intra-logistical processes. The PLANTCockpit will give production supervisors, foremen, and line managers the required visibility to make well-informed decisions for optimizing plant processes. This includes the holistic visibility of the plan, the current status, deviations and exceptions, and bottlenecks.

To achieve this vision, PLANTCockpit targeted the following research and development objectives, which have been extended, focused and defined in more details in the course of project evolution.



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Objective 1: Visibility and integration across all manufacturing processes, layers, and systems

Standardised interfaces: The multi-vendor environment and complexity within any plant makes a harmonization of all systems close to impossible. Therefore, the PLANTCockpit project focused on defining interfaces for integrating the most prominent manufacturing.

Flexible information integration and process orchestration: In practice, most manufacturing operations use industry-specific standards or proprietary interfaces. Therefore, PLANTCockpit defines an approach and architecture to bridge this gap. Information from heterogeneous sources must be aggregated, mapped, transformed, or enriched to match the standardised interfaces. Processes must be orchestrated across multi-vendor system boundaries. The easiness of configuration and usage of the interfaces and components is extremely important for the success of this approach.

Propagation and aggregation of alarms and events: In manufacturing operations, real-time information in the form of alarms and events play an important role. Today, alarms and events are generated and monitored within individual systems. Cross-boundary propagation and aggregation is beyond the state-of-the-art for most current operations. Closing this gap is addressed by the PLANTCockpit architecture. Also higher-level Key Performance Indicators like that characterizing the overall efficiency or energy consumption are in scope of the project.

Visual integration: The design-time and the runtime visualization of the PLANTCockpit require new concepts of integration heterogeneous sources. In order to make the PLANTCockpit concept viable, the effort required for integration must be smaller than state-of-the-art approaches. Even users with little technological know-how but deep domain knowledge shall be enabled to define selected views on plant data and processes. A toolbox with reusable components and templates that provides visual assembly and decision support during the configuration phase has to facilitate these objectives.

Objective 2: Optimized production and logistics processes

Data gathering and bottleneck determination: In order to optimize processes with respect to different and partly competing criteria (like quality and time throughput) much data had to be collected from heterogeneous sources. PLANTCockpit will combine these data and provide views that highlight potentials for process improvements. The user will be able to easily determine bottlenecks and hot spots for needed improvements. Furthermore, the user can influence operations in real-time in order to optimize the process for a particular criterion that is of high importance for that moment in time by accessing the corresponding external systems.

Optimisation through simulation and advanced planning: Simulation-based optimisation and advanced planning (e.g. via genetic algorithms) are outside the scope of the proposed PLANTCockpit project. However, the data model and interfaces provided by PLANTCockpit have to facilitate the integration of simulation and planning tools, e.g. in cooperation with KAP project.



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Objective 3: Increased energy efficiency and reduced waste production

Monitoring: For the definition of PLANTCockpit interfaces, a particular focus will be on the integration to monitoring systems, particularly for energy environmental monitoring. It will be possible to derive detailed information about energy consumption in all forms (water, air, gas, electricity, steam) and waste output. This will create the pre-condition for well-targeted optimization.

Contextualized analysis: The availability of real-time consumption data alone is not sufficient to plan for optimisation. Baseline data is needed about the normal energy consumption of a resource considering different parameters like the current production order, material and tool properties (e.g. milling soft vs. hard metals). This data is derived from the ERP system and further specialized databases. Historical data will need to be added to fully express the meaning of measured consumption data or waste output. PLANTCockpit will provide analytical tools to turn raw data into actionable insight.

Asset optimization through intelligent maintenance: The highest optimisation potential for energy consumption lies in the increased efficiency of production assets like machines. Intelligent maintenance systems like condition-based maintenance (e.g. air flow and pressure monitoring) may be used to quickly identify and address problems. PLANTCockpit addresses also the integration with intelligent maintenance systems.

Research and Development within PLANTCockpit has been accompanied by training measures. Training is essential for the wide adoption and exploitation of the PLANTCockpit approach and technology. The training activities have two objectives: to create awareness on industrial practitioners about the relevance and impact of the developed concepts, in particular for sustainable manufacturing (high-level strategic objective), and to show how the approaches can be implemented through the adoption of tools developed by PLANTCockpit. These tools will be shown to training session participants in order to let them have a clear picture on the possible uses and benefits. Via the immediate experience of composing monitoring and control interfaces the discussion on requirements and need for standardization throughout the industries had to be encouraged. The consortium partners will use existing demonstration and training channels like living labs and extend them further.

All the objectives presented above can have a societal impact only if they will found the way into industry, thus all the objectives had to be supported by accompanying exploitation activities, which may include the transfer of results to the product groups, consulting, analysis and optimization of business processes etc.



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1.4. Main S&T results and their impact

Architecture for production and logistics cockpits

Motivation:

Modern production environments face important problems that prevent users from having an integrated view of the various manufacturing processes and subsequently managing them efficiently and optimizing them. The key challenging areas within the PLANTCockpit context are System interoperability, Data integration, Visualisation, Eventing, Root cause analysis capability and User profiles management. To address these areas, a new architecture supporting the integration and presentation of data from different manufacturing systems in the production and logistic cockpits has been developed.

Main outcomes:

The provided solution comprises a generic layered architecture based on service oriented principles, which combines the openness and flexibility with easy adjustment to the specific use cases. The architecture exploits the concept of reusable Function Blocks, the configurable networks of which are realizing the concrete application scenarios. The architecture is based on 4 principles: Loose coupling between independent layers and between their components, standardized message exchange mechanism, easy configuration of the components on different levels as well as of the entire solution as well as independent and extensible solution.

The architecture is presented in the Figure below.



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Function Engine Layer

PLANTCockpit Reference Architecture

Presentation Engine Layer (Desktop, Mobile)

Persistence Engine Layer

Presentation Runtime

Visualization Engine Layer

Service Engine

Runtime Engine Design Engine

Data Provider Data Point BrowserBuilding Block Browser

External Systems

Devices/S

ensorsERP MES SCADA Excel

Historians/

External DB

3rd Party

SystemsE-Mail

Data Repository

Temp Data (cache)

History Data

Configuration

Repository

Interface for Querying

Push/Pull

System Boundary

System Boundary

Function Blocks

Function Block

Manager

Adapter &

Transformation

Route

Manager

Persistence

Manager

<<create/manages>>

<<create/manages>>

Pub/Sub Broker

Figure 1. PLANTCockpit reference architecture

The architecture follows the concept of the layer-based architecture by describing architecture of separate and independent layers connected by interfaces. This solution permits the creation of layers using different technologies and communicating over uniform interfaces between layers. Because of the independence of the layers, the configuration of the layers can also be independent. For that reason, the architecture is not limited to some specific technologies, but describes the generic functionality of layers. This can be used also as help for selection of specific technologies in the advanced steps of cockpit design. Each layer provides various functional components.

The architecture is described in the public technical D3.3: PLANTCockpit White Paper and D3.5.



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Benefits and users:

The architecture provides a flexible and extensible way of implementation of the production and logistics cockpits. It has been proven by the reference implementation in the PLANTCockpit integrated platform. The architecture can be used by all developers of the cockpits, as well as by potential customers for evaluation of the cockpit solutions. The innovative principles of the architecture have been used in the products developed by the solution providing partners of PLANTCockpit.

PLANTCockpit integrated platform

Motivation:

The PLANTCockpit integrated platform realises the principles and concepts of the PLANTCockpit architecture. On the one hand, it served as a proof of concept for the architecture, on the other hand the implementation of the platform allowed identifying the new requirements and evolving further architectural concepts. It was also a basis for industrial and laboratory prototypes developed in PLANTCockpit.

Main outcomes:

PLANTCockpit integrated platform was implemented based on the open platform of Apache Service Mix and is a reference implementation of PLANTCockpit architecture.

It realises the generic functionality supporting configuration of the platform and of the Function Blocks, eventing and messaging interfaces between platform components, routing and security mechanisms for communication between Function Blocks, components for access and data integration from heterogeneous data sources, data modelling and persistence, implementation the generic components for analytics and visualization etc. The platform includes the following kinds of components:

• Function Block management components

• Messaging and eventing interfaces

• Function Blocks that are realising the process model. To realise the complex scenarios, the Function Blocks can be combined into Function Block networks. The Function Blocks are combined in libraries and thus can be re-used.

• Persistence layer realising the data model.

• Components for access to external systems (adapters).



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Figure 2. The principal architecture of Function Engine

The use case prototypes as well as the integrated demo have been implemented completely on the basis of the PLANTCockpit integrated platform, which allowed its validation and evolution due to emerging requirements coming from the prototype implementation.

The core components of the platform (Function Engine) are will be developed and distributed further by the consortium partners after the end of the project as an open source solution with TU Tampere having a role of proxy for this, which will be in mainly responsible for maintaining and distributing of the Function Engine. The corresponding agreements have been set up by partners. The platform is accessible at http://www.tut.fi/plantcockpit-os, see a screenshot in Figure 3.



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Figure 3. Screenshot of the webpage of Function Engine.

Benefits and users:

The integrated platform as the reference implementation of the PLANTCockpit architecture allowed demonstration of its main concepts and advantages. The practical benefits of the prospective users



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of the platform and of concepts include a quicker setup of the platform due to uniform configuration mechanisms, better visibility of the processes due to tight integration of different systems and data presentation on different devices, as well as more precise and quick decision making due to advanced analytics.

The core components of the platform (Function Engine) can be used directly or adjusted by the developers of production and logistics cockpits.

Industrial and laboratory prototypes

Motivation:

To achieve the practical impact of the project, a set of industrial and laboratory prototypes has been envisioned in the Description of Work, which would provide the proof of developed concepts in practical applications in different areas. Further, the demonstrators served as a source of additional requirements appearing in course of prototypes development.

Main outcomes:

For specific use cases of the industry partners of PLANTCockpit, the corresponding prototypes have been realized by configuration of the Function Blocks and implementing their specific functionality, demonstrating the practical applicability of the platform. The following six industrial prototypes have been developed based on the PLANTCockpit integrated platform and using the practical data and environments of industrial partners:

• KPI tracking prototype inspired by automotive industry, which facilitates the analysis of dependencies between KPIs and root-cause analysis.

• Material and order tracking prototype inspired by food and beverages industry, giving the overview of processed products and orders, as well as stock status of necessary materials. The prototype allows quick identification, analysis and solving of the supply and production issues, like missing materials, deviations from production plans, supply bottlenecks, as well as what-if and action scenarios.

• Two asset utilization prototypes for automotive industry and for building construction materials production, which allowed the visualization of orders and plans, as well as of the status of machines and their utilization. This allows improving the grade of machine utilization and their efficiency, as well as quicker solving of the production issues.

• Two energy optimization prototypes for semiconductor manufacturing and for automotive industry. They allowed visualizing the current status and forecasting of the consumption of energy in different form and other environment-relevant materials, CO2 emission etc., as well as identification of deviations and bottlenecks. Further, it was shown how the energy optimization can be coupled with the planning of the production orders and machine



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utilization to optimize the energy consumption, e.g. by turning off the machines, as well as how the output of these measures can be assessed.

Comparison and combination of the prototypes enabled extraction of the features common for the different industrial domains, as well as of the specific ones. All prototypes have been tested and evaluated on the sites of industrial project partners.

The implementation of the industrial prototypes came hand in hand with the implementation of the laboratory prototypes, which allowed the first testing of the concepts and early prototypes in the laboratory environments, and vice versa the industrial prototypes have been adjusted to the laboratory prototypes to demonstrate the project outcomes to broader audience in the course of the project and beyond it. SAP Future Factory in Dresden and the Living Lab of Tampere University of Technology have been used as laboratory environments, along with the web-based lab environment running on facilities of Iconics. These laboratory prototypes will continue running also after the project end to disseminate the project concepts. All implemented industrial and laboratory prototypes have been combined into the integrated demo, representing the different aspects of industrial application of the cockpits on a hypothetical manufacturing company. The integrated demo will be used by the consortium partners for teaching and demonstrating purposes. Based on the components developed for the use case prototypes, the generalized components could be developed.

Benefits and users:

The developed prototypes are demonstrating and validating the main concepts of the project in the practical environments from the different industrial domains. The results mirrored in the several public reports, publications and prototypes can be used in the corresponding domains by decision makers, production responsible persons and cockpit developers.

The use case partners of PLANTCockpit will use the prototypes and evaluation results in their business and in decision making for future software and systems acquisitions. The concepts developed in the course of prototype implementation are being transferred into the future features and products by solution providers.

Business process analysis

Motivation:

In course of analysis of detailed requirements on the production and logistics cockpits, the use case partners had to assess the current state of their business processes and identify the need for gaps and detailed features.

Main outcomes:

The description of the business processes of five use case partners (Acciona, BMW, Comau, Doehler, Intel) have been comprised in the corresponding deliverable D2.2 and made public in the

PLANTCockpit Brochure on Use Cases, which contain the description of the company and



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industrial domain, the current business processes and gaps, as well as the detailed requirements. The requirements have been aligned, classified and the concrete prospective features have been derived, based on which the PLANTCockpit architecture, platform and prototypes have been developed.

Since an extremely high number of the requirements from quite different domains have been collected, a special methodology for their analysis had to be developed, which is summarized in

D2.1: Method to Collect, Document and Analyse User Requirements and in the corresponding publication.

Benefits and users:

For the first time, the requirements on cockpits from such different industrial domains have been collected and analysed, which allowed to get a cross-domain view on the need of industry. This knowledge can be used by business experts in different domains.

For industrial partners of PLANTCockpit, this was a great opportunity to assess their process models, which is the basis for analysis and optimization and immediately impacts the everyday business of these partners. For the solution providers, this analysis helped to shape their development strategy, to identify and prioritize the new features and prospective products.

Visualization Engine

Motivation:

One of key goals of product cockpits is supporting integrated manufacturing operations by providing relevant and timely information adapted to the context of specific users, as well as easy configuration and use of such cockpits. Only by visual integration and user perception support the monitoring and control of the modern complex manufacturing systems can be manageable.

Main outcomes:

The flexible visualization framework called Visualization Engine has been implemented as one of layers of the PLANTCockpit architecture. It has been developed on the basis of user requirements and of analysis in the report T6.1: Visualization Framework, which presents a comprehensive compendium of state of the art of flexible visualization frameworks, providing background and fundamental principles of visualization design as well as overview of the visualization frameworks and their evaluation. In order to avoid information overload, the report also defined core visualization that provides perceptually efficient means for monitoring the overall systems state.

Visualization Engine was implemented using .Net and HTML5 technologies, which allows data presentation on both desktop and mobile devices. Visualization Engine comprises a set of generic visualization components (Building Blocks) like tables, gauges, charts etc., which can be easily re-used and adjusted for specific use cases using the Designer UI, cp. Figure 4.



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Figure 4. Screenshot of Designer UI for configuration of chart components.

Further, a set of generic components for managing of building blocks has been developed, which includes design-time composer, configuration and communication interfaces etc., which facilitate the configuration and usage of the visualization without having deep programming skills. The implemented prototypes have used the Building Blocks for the presentation of their data. Based on the visualization engine, the advanced visualization features have been implemented and tested, which facilitate e.g. analysis of dependencies between key performance indicators, presentation of historical and actual states of the system, presentation of data from heterogeneous systems etc. An example of the configured dashboard is shown in the screenshot on Figure 5.



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Figure 5. Example of the dashboard composed from Building Blocks of PLANTCockpit Visualization Engine.

Benefits and users:

The report T6.1 can be used by developers of the new visualization solutions for state of the art analysis, as well as by potential customers of cockpit solutions to get an overview of the modern visualization tools.

The developed Visualization Engine has been used in all prototypes and demonstrators of PLANTCockpit. The developed concepts and proofs of concepts for the Visualization Engine have been transferred into the product Genesis 64 / Mobile HMI of Iconics. The selected visualization concepts and architectural principles for the visualisation have found their way into the products of SAP. Several publications on the advanced visualization concepts contribute to the state of the art in the area of visualization of production and logistics data.

Approaches for KPI analysis

Motivation:

The massive grow of information from different production and logistics systems that has to be analyzed by experts requires new analysis and visualization methods. Typical examples of business information for decision making are key performance indicators (KPIs), which are an important instrument to get status of manufacturing, logistical and other business processes, and to analyse them. Different kinds of KPIs are used in different domains, enterprises, and areas within one enterprise which impedes their analysis and requires their unification. Further, it is important not only to analyse the KPIs separately from each other, but in their whole unity, which requires modelling and analysing the dependencies between them.



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Main outcomes:

The KPIs from different manufacturing domains and levels have been analysed and combined in the KPI catalogue, which comprises the practically used KPIs, their different dimensions and calculation instructions in a unified description. The special focus was made on energy-related and environmental KPIs.

To facilitate re-use and adjusting of KPIs to specific industries and use cases, a concept of abstract and instance KPIs has been introduced. The concept was implemented in a specific data model for KPI analysis, which is a part of PLANTCockpit persistence layer and can be used by the users of cockpits independent of their domain. The data model supports among others modelling of interdependencies between KPIs, which reflect such relations as influencing factors, root-cause relations etc. and enable a much deeper insight into the manufacturing systems. For example, it helps to identify the causes of occurred problems, their possible consequences, alternatives etc. An example of visualization in Figure 6 demonstrates that the critical KPI K may influence the KPI T, so that a kind of what-if analysis can be provided.

The modelling of KPI dependencies has also indicated the need for the advanced visualization features helping to cope with the complexity and heterogeneity of the information presented in the cockpits. The new methods developed in PLANTCockpit allow simultaneous presentation of several kinds of relevant information on one screen, easy switch between different aspects, dive-in into details, as well as focusing and highlighting. This substantially extends the limitations of current dashboards.

Figure 6. Presentation of status and dependencies of KPIs in PLANTCockpit

Benefits and users:

The KPI catalogue can be used by industrial user groups and organizations to align their KPI systems and introduce the new ones. It has been introduced also to European standardization bodies to shape the future standards. The data model and its reference implementation in the persistence manager are relevant for the developers of future cockpits.



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The developed concepts for KPI analysis have been transferred into the products of SAP as well as integrated into the prototypes of other partners. Advanced visualization concepts will shape the visualization metaphor of the developers in the partners’ organizations in the long term.

Approaches for interfaces, security, persistence and configuration

Motivation:

During the implementation of the PLANTCockpit platform, new challenges in the design of integrated cockpits and, more generally, system integration have been identified. Although the modern integration frameworks like Apache ServiceMix already support a lot of features for initialization and communication between components and their runtime support, the definition of interfaces and configuration of the component communication still requires a lot of programming or scripting efforts, which impedes the implementation of these systems.

Main outcomes:

PLANTCockpit has developed the approaches, proof of concepts and corresponding components for the following aspects of the system integration:

• Uniform common interfaces (message types) for communication between Function Blocks in form of XML messages, which standardize and simplify the development and verification of the communication between components.

• Eventing and routing mechanisms for notification of components and correct transferring of messages between them.

• Security mechanisms for the access to the cockpit components and data sources based on user roles, allowing to define the access to only the components and data sources that the user is qualified for.

• Persistence mechanisms for easier and flexible setting up the corresponding data models using the object-relational mapping, which avoids the elaborative manual data modelling and delivers the necessary data models out of the box.

• Configuration support for the components and their routing. To realize a complex analytic scenario involving a row of components, a lot of XML files and other configurations would have to be adjusted when using common integration frameworks. Contrary to that, PLANTCockpit has implemented a graphical user interface, where the Function Block Networks can be created by the convenient drag and drop of Function Blocks from corresponding libraries with subsequent script configuration of the Function Block instances and routes between them, cp. Figure 7.

The developed approaches have been implemented in the PLANTCockpit platform. The corresponding publications and patents are in preparation.



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Figure 7. Screenshot of web-based Function Block Engine Configurator of PLANTCockpit

Benefits and users:

The developed approaches present the next step in the configuration of component and system integration for cockpits, where on the one hand the common approaches and interfaces are created that simplify the work of the developers, and on the other hand the end users are supported by graphical user interfaces which partly take over the work of the configuration. This allows realizing more complex systems and facilitates their implementation, from which the developers of such systems will benefit.

Methods and components for data access and integration

Motivation:

The production and logistics cockpits have to access different external information systems like shop floor systems, enterprise resource planning, manufacturing execution, business analytics etc., as well as to integrate the data from these systems in common views. This requires the corresponding configuration efforts, since the external systems provide different interfaces, deliver



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the data in different formats and semantics. Manual configuration for data access and integration is a laborious and error-prone task, which should be supported by (semi-)automatic methods.

Main outcomes:

PLANTCockpit facilitates the access to external systems in the corresponding layer, which is a part of the Function Engine. It introduces the concept of adapters, which are special Function Blocks encapsulating the functionality of access to the external systems and converting the data into the internal message formats of PLANTCockpit. For each external system type, the corresponding adapter type should be used. To connect to the external systems, the adapter should be instantiated and configured. A row of adapters to relevant systems has been implemented, including adapters to OPC-UA, databases, web services, DPWS, SAP Business Warehouse, SAP ERP, MS Excel, MS Project. The open concept of adapters facilitates the developing of different cockpits and reports, as well as allows the later implementation of any further types of adapters.

Since the configuration of adapters still has to be made manually, an approach for (semi-)automatic configuration of adapters based on semantic information has been developed. It exploits the domain-specific production ontologies to derive the configuration data necessary for the specific adapter and subsequent Function Block. The corresponding graphical user interface has been developed, along with the proof of concept based on PLANTCockpit platform.

Benefits and users:

The concept of adapters allows seamless integration of the PLANTCockpit function blocks and external systems by separation of the access details and semantics. As result, the users can quickly and transparently access different external systems and realize the cockpit views and further analytical scenarios without knowing the details required by external systems. This accelerates setting up and usage of cockpits and enables new variants of their usage. All implemented prototypes are using the adapters.

1.5. Matching of objectives and results The matching of the project objectives and results is given in Table below. As conclusion of this table, all project objectives have been completely fulfilled.

Table 1. Matching of objectives and results.

Objective Results

Visibility and integration across all manufacturing processes, layers, and systems

PLANTCockpit architecture and platform

Standardised interfaces Approaches for interfaces, persistence and configuration



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Flexible information integration and process orchestration

PLANTCockpit platform

Approaches for interfaces, persistence and configuration

Propagation and aggregation of alarms and events

Approaches for interfaces, persistence and configuration

Visual integration Visualization Engine

Optimized production and logistics processes




Data gathering and bottleneck determination Methods and components for data access and integration

Material tracking prototype

Optimisation through simulation and advanced planning

Energy optimization prototypes

Approaches for KPI analysis

Increased energy efficiency and reduced waste production




Monitoring PLANTCockpit platform

Methods and components for data access and integration

Contextualized analysis Approaches for security and configuration

Visualization Engine

Asset optimization through intelligent maintenance

Asset utilization prototypes



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2. Use and dissemination of foreground The report and plan on dissemination and use of the foreground is provided in the Sections A and B of this section.

Section A (public)

A statistical summary of dissemination activities that have been conducted can be seen in Figure 8 and Figure 9. In total, 17 conference and journal publications, 7 presentations at fairs, 1 special session and 27 project presentations have been provided.

Further, this section includes two tables:

o Template A1: List of all scientific (peer reviewed) publications relating to the foreground of the project.

o Template A2: List of all dissemination activities (publications, conferences, workshops, web sites/applications, press releases, flyers, articles published in the popular press, videos, media briefings, presentations, exhibitions, thesis, interviews, films, TV clips, posters).

These tables are cumulative, which means that they show all publications and activities from the beginning until after the end of the project.

Additionally to this, the public web page of the project (www.plantcockpit.eu) provides the open access to the details of the project, including the following materials:

o More than 15 technical reports and training materials that provide a detailed insight into the different technical and business aspects of the project results and give the practitioners the guidelines on implementing und using the production and logistics cockpits.

o Screenshots of the prototypes and photos of the laboratory facilities and dissemination events

o Links to videos

o Links to further materials on the side of partners and their contact data.

o The web page will run at least 1 year after the project finish to ensure the sustainability of results.



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Figure 8. Dissemination activities displayed by their type

Figure 9. Dissemination activities over the project runtime



25

TEMPLATE A1: LIST OF SCIENTIFIC (PEER REVIEWED) PUBLICATIONS, STARTING WITH THE MOST IMPORTANT ONES

NO. Title Main author Title of the

periodical or the series

Number, date or

frequency Publisher Place of

publication Year of

publication Relevant

pages

Permanent identifiers1 (if

available)

Is/Will open access2

provided to this

publication?

1

Layered Architecture for Production and Logistics Cockpits

Volodymyr Vasyutynskyy

IEEE ETFA 2012

September 17-21. 2012

Krakow, Poland 2012 1-9

http://dx.doi.org/10.1109/ETFA.2012.6489548 no

2

Modeling and Presentation of Interdependencies between Key Performance Indicators for Visual Analysis Support Stefan Hesse

Advances in Production Management Systems. Competitive Manufacturing for Innovative Products and Services 2012

24.-26. September 2012

Springer Berlin Heidelberg

Rhodes Islands, Greece 2012 281-288

http://dx.doi.org/10.1007/978-3-642-40361-3_36 no

3

An Approach for a Component based Visualization of Data from Heterogeneous Manufacturing Sources Stefan Hesse

Emerging Technologies & Factory Automation (ETFA), 2012 IEEE 17th Conference on

September 17-21. 2012

Krakow, Poland 2012 1--5

http://dx.doi.org/10.1109/ETFA.2012.6489751 no

4 Vertical Data Integration in Automation based on IEC

Alexander Dennert

IEEE WFCS 2012

May, 21.24. 2012

Lemgo, Germany 2012 99-102

http://dx.doi.org/10.1109/WFCS.201 no

1 A permanent identifier should be a persistent link to the published version full text if open access or abstract if article is pay per view) or to the final manuscript accepted for publication (link to article in repository). 2 Open Access is defined as free of charge access for anyone via Internet. Please answer "yes" if the open access to the publication is already established and also if the embargo period for open access is not yet over but you intend to establish open access afterwards.



26

61499 2.6242551

5

Approach on Analysis of Heterogeneous Requirements in Software Engineering

Andreas Koukias

11th IFAC Workshop on Intelligent Manufacturing Systems, IMS 2013,

22-24.May 2013

Sao Paulo, Brazil 2013 372-377

http://dx.doi.org/10.3182/20130522-3-BR-4036.00088 No

6

Advanced Concepts for Flexible Data Integration in Heterogeneous Production Environments

Alexander Dennert IMS 2013 22.05.2013

Sao Paulo, Brazil 2013 348-353

http://dx.doi.org/10.3182/20130522-3-BR-4036.00047 no

7 ISA-95 Tool for Enterprise Modelling Dazhuang He ICONS 2012 05.03.12

Saint Gilles, Reunion Island 2012

8

Evaluating Service-Oriented Orchestration Schemes for Controlling Pallet Flow

Johannes Minor ICONS 2012 05.03.2012

Saint Gilles, Reunion Island 2012

9

Assessment of IEC-61499 and CDL for Function Block composition in factory-wide system integration TUT INDIN 2013 July 2013

Bochum, Germany, July 29-31, 2013 2013

http://dx.doi.org/10.1109/INDIN.2013.6622884

10

An approach for OSGi and DPWS interoperability: Bridging enterprise application with shop-floor TUT INDIN 2013 July 2013

Bochum, Germany, July 29-31, 2013 2013


11

Creating an interactive graph-based visualization of performance indicators for decision support Stefan Hesse

IHCI'2013, IADIS International Conference on Interfaces and Human Computer Interaction 2013,

July 22 - 24 2013

Prague, Czech Republic 2013 71--78 n.a. no

12 Reference model concept for structuring and Stefan Hesse

Advances in Production

24.-26. September

Springer Berlin

Rhodes Islands, 2012 289-296

http://dx.doi.org/10.1007/978-3-642- no



27

representing performance indicators in manufacturing

Management Systems. Competitive Manufacturing for Innovative Products and Services 2012

2012 Heidelberg Greece 40361-3_37

13

Visual Analysis of Performance Indicators and Processes in Modern Manufacturing

Volodymyr Vasyutynskyy

GCSM2013, 11th Global Conference on Sustainable Manufacturing

Sept 23-25, 2013

Berlin, Germany 2013 n.a. n.a. n.a.

14

Improving Energy Efficiency in Manufacturing via KPI intelligence based on Plant Integration Gökan May GCSM 2012

Oct. 31-Nov 2 2012

Istanbul, Turkey 2012 423-428 No

15

OPC-UA and DPWS Interoperability for Factory Floor Monitoring using Complex Event Processing

Jorge A. Garcia Izaguirre M.

INDIN conference

26th-29th July 2011

Caparica, Lisbon, Portuga 2011 205 - 211


16

An integrated requirements elicitation approach for the development of data management systems

Frederic Demoly

PLM2011 (International Conference on Product Lifecycle Management)

11th.-13th July 2011

Eindhoven, Netherlands 2011

17

Enhanced Energy Management in Manufacturing through Systems Integration Gökan May IECON 2013

Nov 10-13 2013

Vienna, Austria 2013 N/A No



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TEMPLATE A2: LIST OF DISSEMINATION ACTIVITIES

NO. Type of activities3 Main leader Title Date/Period Place Type of audience4

Size of audience

Countries addressed

1 Project presentation SAP

5th IT-Summit of the German Federal

Government 7th December

2010 100 Germany

2 Industry fair SAP CeBIT 2011 1st - 5th March

2011 Hanover, Germany

Industry, general 500 Germany

3 Project presentation ICONICS university of Bohemia 28th February

2011 Bohemia Academic Czech Republic

4 Project presentation ICONICS 2011 ICONICS World

Wide Customer Summit 29th. June- 01st

July 2011 Newport (Boston) worldwide

5 Presentation SAP Output DD 6.0 13th May 2011 Dresden Academic, Industry 300 Germany

3 A drop down list allows choosing the dissemination activity: publications, conferences, workshops, web, press releases, flyers, articles published in the popular press, videos, media

briefings, presentations, exhibitions, thesis, interviews, films, TV clips, posters, Other.

4 A drop down list allows choosing the type of public: Scientific Community (higher education, Research), Industry, Civil Society, Policy makers, Medias, Other ('multiple choices' is possible).



29

6 Key Note Presentation SAP

Customer Event of ICONICS in Boston/US with 400 participants

29th June – 1st July 2011 Boston Industry 400 USA

7 Project presentation ICONICS ICONICS 360 Degrees

Customer Summit 8th November 2011

Santa Margherita Ligure (Genoa, Italy) Industry Italy

8 Project presentation SAP

World Usability Day Workshop at TU

Dresden 10th November 2011 Dresden Academic 50 Germany

9 Project presentation TUD

Booklet about the Faculty of Computer Science (Technische Universität Dresden) July 2011 Dresden general press 500 Germany

10 Booth SAP

CeBIT 2012, Hanover, Germany,

PLANTCockpit booth as a part of Factories of the

Future booth 6-10 March 2012 Hanover, Germany Industry 500 European/Germany

11 Presentation SAP "ICT & Factories of the Future" conference, 6 March 2012

Industry, Academic 500 worldwide

12 Presentation Tecnalia, SAP

2nd Workshop on Impact of the Factories of the Future PPP 15-16 March 2012 Brussels

Industry, Academic European

13 Industrial Fair Tecnalia Bilbao www.biemh.com 05.28 -

Bilbao Industrials Spain



30

06.02.2012

14 Project description in EFFRA Flyer SAP EFFRA Flyer Nov 12

Academic, Industry 100 European

15 Project presentation POLIMI

Industrial Technologies 2012 Congress and Exhibition June 2012 academic worldwide

16 Project presentation POLIMI

APMS International Conference , session “Global Research Activities in Energy and Resource Efficient Manufacturing” September 2012 academic worldwide

17 Electronic journal article ICONICS Control Engineering Europe June 2012 industrial European

18 project Presentation ICONICS Zero Emission Show September 2012 Rome, Italy industrial Italy

19 Industrial journal paper SAP IT&Production (Industry-oriented journal) September 2012 industrial 1000 Germany

20 Industry exhibition ICONICS SPS/IPC/DRIVES 2012, exhibition booth November 2012

Nuremberg, Germany industrial European

21 Presentation ICONICS SPS-IPC-Drives November 2011 Nuremberg, Germany Industrial European

22 Project presentation TUD Honeywell Automationstage 2012

September, 20th, 2012 industrial 50 Germany



31

23 Project presentation EPFL GCSM 2012 31.October-2nd November 2012 Istanbul, Turkey academic worldwide

24 Demo presentation SAP DKOM'2013 DemoJam, 13.03.2013 Bangalore industrial 400+Stream worldwide

25 Demo presentation SAP DKOM'2013 DemoJam, 26.03.2013 Paris industrial 400+Stream worldwide

26 Presentation POLIMI GCSM 2012 Istanbul, Turkey academic worldwide

27 Presentation ICONICS Internal Sales Meeting January 2013

28 Demo presentation, Industry exhibition ICONICS

Customer visit, PHOENIX CONTACT, Germany January 2013 Industry Germany


Customer visit, JOHNSON CONTROLS, Germany March 2013 Industry Germany


Trade Show, Hannover Messe April 2013

Hanover, Germany

Academic, Industry European

31 Demo presentation, Industry exhibition Intel

Digital Dublin Open Innovation 2.0 May 20-21 2013 Dublin

Academic, Industry Ireland

32 Workshop Intel ICMR/i2e2 Technology Expo Nov 12 2012

Academic, Industry Ireland

33 Demo presentation TUT Manufuture 2013 Oct 2013 Vilnius Academic, Industry worldwide

34 Video TUT Manufuture 2013 Oct 2013 Vilnius Academic, Industry worldwide



32

35 Dissemination material and presenattion PC Manufuture 2013 Oct-2013 Vilnius

Academic, Industry, Policy makers European

36 Conference special session POLIMI IECON 2013 Nov 13 Vienna Academic, Industry worldwide

37 Project presentation TUT ICT 2013 Nov 2013 Vilnius

Academic, Industry, Policy makers European

38 Researcher’s Corner ACCIONA Internal R&D Magazine for Acciona’s employees Nov 2013 Madrid, Spain Industry

Acciona employees - 30000 Spain

39 Acciona’s web site ACCIONA Official Web site of ACCIONA Nov 2013 Madrid, Spain Industry worlwide worldwide

40 Acciona’s web site ACCIONA Intranet for Acciona’s employees Dec 2013 Madrid, Spain Industry

Acciona employees - 30000 Spain

41 Workshop Platte Consult

WORKSHOP: Cyber-Physical Systems in manufacturing and production Nov 13

Brussels, Belgium

Academic, Industry worldwide

42 Project presentation EPFL GCSM 2013 23rd -25th September 2013 Berlin, Germany academic worldwide

43 Project presentation EPFL Exprts round table "Factories of the Future"

1st November 2013

Geneva, Switzerland Industry worldwide



33

44 Project presentation, standardization presentation EPFL

Joint Dissemination Conference - Imagine FOF2020

12th-14th June 2013

Geneva, Switzerland

Industry, Academic worldwide

45 Press release ACCIONA ECTP´s web site Nov 2013 Madrid, Spain Industry, Academic worldwide

46 Project web page TUD/SAP PLANTCockpit : Home - Dresden all na worldwide

PROJECT FINAL REPORT - European Commission ...cordis.europa.eu/docs/projects/cnect/8/260018/080/...Cooperation Collaborative project (IP) 260018 PLANTCockpit FP7-2010-NMP-ICT- FoF

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