Www.mesa.org 2009 European Plant-to-Enterprise Conference October 27-28, 2009, Utrecht, The Netherlands Mdf MES Development Framework Massimiliano Papaleo.

www.mesa.org 2009 European Plant-to-Enterprise ConferenceOctober 27-28, 2009, Utrecht, The Netherlands

MdfMES Development Framework

Massimiliano PapaleoMdf Project Manager

MES is a solution

• ERP communication (master data, orders, consumptions)

• Collect data from field

• Overall equipment effectiveness

• A manufacturing execution system CAN’T be a product

Mdf is a library

Mdf - MES Development Framework• Microsoft .NET library• Manage all MES data

– Resources (Material, Equipment, Personnel)– Combined resources (Process segment, etc)– Production (Product, Scheduling,

Performance)– Utilities (Sequences, Parameters, etc)– Security management

Mdf is a tool

With a web application the user can

• Manage the master data

• Configure the plant resources

• Manage all the collected data

With the Visual Studio Addin

• Build classes automatically

• Create tables automatically

Mdf is ISA-95 compliant

• Resources models• Combined resources

models• Production process

product models• Database tables• Classes

Corresponds to a

Segment Response

Resource Actual

Production Response

Production Performance

Production Performance

What was made & used in

ptoduction

Segment Requirement

Resource Requirement

Production Request

Production Schedule

Production Scheduling What is it to be made & used in

production

Product Segment

Resource Specification

Production Rule

Product Definition What must be

defined to

make a product

Resource Segment

Specification

Process Segment What can be

generally done

with the resources

Corresponds to a

Corresponds to a

Corresponds to a

Corresponds to a

Corresponds to a

Corresponds to a

Process Segment

Who can use Mdf

• System integrators

• MES designer

• Plant IT internal developer

May contain 1 or more

May contain 1 or more May contain 1 or more

May contain 1 or more

May contain 1 or more

May contain 1 or more

May contain 1 or more

Enterprise

Site

Area

Production unitProcess cell Production line

Unit Work cell

DB

An Mdf-MES architecture

• SQL Sever as storage layer

• Mdf framework as application layer

• Business rules as custom application layer

• Mdf portal and custom interface as web user interface layer

Navigate through ISA-95

The Mdf portal is a web application used to:• Manage master data• Configure plant resources• Manage all collected data

Business rules

• Business rules are useful to model the production needs

• Business rules written in C#– Fast execution– Windows Workflow

Foundation engine can process the rules

B2MML

• B2MML: XML implementation of the ISA-95

• Mdf implements all the standard entities in a framework of over 200 .NET classes B2MML compliant

• Mdf can to import/export the plant configuration using XML files

OPC interface

• OLE for Process Control (OPC): standard which defines the communication between etherogeneous control devices

• Mdf uses OPC to communicate with PLCs and field devices

Microsoft technologies

• Microsoft .NET Framework ensures:– System longevity– Full compatibility with new operating systems– High performances

• Entity framework makes easy to access data from any source

Resources

• Equipments

• Materials

• Personnel

• Orders

• Project entities

Equipment Class

Equipment Capability Test Specification

Equipment

Equipment Capability Test

Result

0..n

0..n

Defined by

0..n 0..n

1..n 0..n

0..n

Maintenance Request

Maintenance Work Order

Maintenance Response

1..1 1..1

0..n

0..n

0..n

0..n

0..1

0..n

1..1

May be made up of

May be generated for

May result in

Is made against

Is against

Class Custom Class Custom ElementCustom Properties: Property List

Custom Class Property

May contain

0..n

May contain

Defined by0..n0..n0..n

Combined resources

• Process segment• Process segment

capabilities• Production capabilities

Process Segment Capability

Resource Segment Capability

Process Capability What can be done with the

resources

Production Capability Utilization

Resource Capability Utilization

Production Capability Utilization

What resources

are/were used

Corresponds to a

Production Capability

Resource Capability

Production Capability

What resources

are/will be available

Corresponds to a

Process Segment

Resource Segment

Specification

Process Segment What can be

generally done

with the resources

Process Segment Capability Utilization

Resource Segment Capability Utilization

Process Capability utilization

What was done

with the resources

Corresponds to a

Corresponds to a

Corresponds to a

Corresponds to a

Corresponds to a

May be

compa

red to o

btain OE

E

May be

compa

red to o

btain OE

E

Corresponds to a

Production process product

• Product definition information

• Production schedule• Production

performance• Production capability

utilization Corresponds to a

Segment Response

Resource Actual

Production Response

Production Performance

Production Performance

What was made & used in

ptoduction

Segment Requirement

Resource Requirement

Production Request

Production Schedule

Production Scheduling What is it to be made & used in

production

Product Segment

Resource Specification

Production Rule

Product Definition What must be

defined to

make a product

Resource Segment

Specification

Process Segment What can be

generally done

with the resources

Corresponds to a

Corresponds to a

Corresponds to a

Corresponds to a

Corresponds to a

Corresponds to a

Process Segment

Process order management

• Order activation and order deactivation

• Production recipe• Viewing of product set-points

relating to the production segment

• Order closure • Used materials and equipments

storage• Operators identification• Set-up duration storage• Archive of rejects• Archive of downtime

0..n

May contain

0..n

0..n

Corresponds to element in

0..n0..n

0..n

Production Perfoemance

Production Response

Segment Response

Process Segment

Production DataMaterial

Consumed Actual

Consumable Actual

Personnel Model

Equipment Model

Material Model

1..1

1..1

1..1

1..1

Corresponds to a

Is made up of

Is made up of

1..n

1..n

Equipment Actual

Material Produced Actual

Personnel Actual

Corresponds to element in

Corresponds to element in

Corresponds to element in

Collect production data

• Using Mdf through the OPC client is possible to collect production data directly from plant machines

Traceability

• Traceability refers to the completeness of the information about every step in a process chain

• Using Mdf is possible to:– Keep track of all the components and data

that contribute to the formation of product quality

– Uniquely identify all the units of the production

Collect OEE

• Overall equipment effectiveness (OEE):hierarchy of metrics which describes how effectively a manufacturing operation is utilized

• Mdf offers several functions at different levels:– Availability rate– Performance rate– Quality rate

Warehouse management

• Warehouse operations: Equipment hierarchical structure, handling unit and custom order entities make possible a straightforward management

Reporting

• SQL Server as database server– Advanced reporting services used to generate

production reports

• Reporting services allow showing the statistical and historical maintenance data

Documentation

Part 1• ISA - 95 and MES

application• Equipment hierarchical

model• B2MML• Mdf: ISA-95 and Visual

Studio .NET• Mdf architecture• LINQ to Entity• Workflow Foundation

Mdf – Bible

Part 2• Install and configure Mdf• Model MES application• Custom production rule

interface• Custom production

schedule interface• Collect production data

Part 3• Reporting• Traceability• Collect OEE

Thanks for listening

Massimiliano Papaleo

EmPy studio – IT Plant Solutions

www.empystudio.com

[email protected]

[email protected]