WW OPS-11
Wonderware Workflow:A Plant Engineer's Perspective
Roger SmithWonderware Solutions Architect
@InvensysOpsMgmt / #SoftwareRevolution
/InvensysVideos
social.invensys.com
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
Roger SmithWonderware Solutions Architect /Wonderware
/company/Wonderware
Session Topics & Objectives
Challenges for Enterprise & Industry
Opportunity & Objectives for Remedy
Workflow & Business Process Management
Applying Wonderware Workflow to the Industrial Space
Building on Wonderware System Platform Infrastructure
Examples of Wonderware Workflow in Action
Slide 3
Challenges for Enterprise & Industry
Opportunity & Objectives for Remedy
Workflow & Business Process Management
Applying Wonderware Workflow to the Industrial Space
Building on Wonderware System Platform Infrastructure
Examples of Wonderware Workflow in Action
Real-World Challenges…
Many Data Sources:• ERP
– Orders/Finished Goods
– Raw Materials
• Quality/LIMS
• Ops Management– Process Specifications
– Consume/Produce/WIP
– Asset Performance/OEE
– Historian
• Maintenance EAM/CMMS
Many Roles:• Operations
• Maintenance
• Quality
• Safety
• Environmental
• Supply Chain
• Finance
• Corporate
Many Systems:• Enterprise Applications
– ERP, EAM/CMMS, Custom DB
• Automation Applications– PLC, DCS, HMI, SCADA, MES
• Desktop Applications– Word, Excel, Outlook, Visio
• Web-Based– Custom Portal, SharePoint
• Manual – Human Decision– Voice, Text, Email
Slide 4
Many Data Sources:• ERP
– Orders/Finished Goods
– Raw Materials
• Quality/LIMS
• Ops Management– Process Specifications
– Consume/Produce/WIP
– Asset Performance/OEE
– Historian
• Maintenance EAM/CMMS
Many Roles:• Operations
• Maintenance
• Quality
• Safety
• Environmental
• Supply Chain
• Finance
• Corporate
Many Systems:• Enterprise Applications
– ERP, EAM/CMMS, Custom DB
• Automation Applications– PLC, DCS, HMI, SCADA, MES
• Desktop Applications– Word, Excel, Outlook, Visio
• Web-Based– Custom Portal, SharePoint
• Manual – Human Decision– Voice, Text, Email
The BIGGER Challenge –System to People Collaboration
System
ManualProcess
AutomatedProcess
Slide 6
System
System
ManualProcess
ManualProcess
AutomatedProcess
Challenges Unique to Industry
• Automation systems not connected to othersystems in real-time.
• Automation & Information Systems aren’ttightly and methodically connected to humanaction/reaction.
• Results negatively impact the business:
−Automated processes become semi-manual.
−Operation is inconsistent or untimely.
−Records of action lacking or non-existent.
Slide 9
• Automation systems not connected to othersystems in real-time.
• Automation & Information Systems aren’ttightly and methodically connected to humanaction/reaction.
• Results negatively impact the business:
−Automated processes become semi-manual.
−Operation is inconsistent or untimely.
−Records of action lacking or non-existent.
Industrial Challenges:OperationsHuman activities surrounding the process:
– Machine setup, process changeover.
– Manual operation of peripheral components.
– Change in upstream/downstream process.
Unexpected or unpredictable operation:
– Events: Equipment failure, materials outage, waste, spill, emissions
– Cost Variance: Excessive time, energy, labor, materials, rework
Response to alarms detected by Automation System:
– High level, low temperature, no output.
– Safety systems, interlocks, guard systems.
Slide 10
Human activities surrounding the process:
– Machine setup, process changeover.
– Manual operation of peripheral components.
– Change in upstream/downstream process.
Unexpected or unpredictable operation:
– Events: Equipment failure, materials outage, waste, spill, emissions
– Cost Variance: Excessive time, energy, labor, materials, rework
Response to alarms detected by Automation System:
– High level, low temperature, no output.
– Safety systems, interlocks, guard systems.
Industrial Challenges:Post-Activity InformationInformation captured with process context:
– Time-series process data
– Alarm & Event History
– Utilization/OEE
– Energy Consumption & Intensity
– Genealogy/Traceability
– Asset Health & Runtime Information
– Data Analysis & Dashboards
None of the above report systems “do something”.
Slide 11
Information captured with process context:
– Time-series process data
– Alarm & Event History
– Utilization/OEE
– Energy Consumption & Intensity
– Genealogy/Traceability
– Asset Health & Runtime Information
– Data Analysis & Dashboards
None of the above report systems “do something”.
Inevitability: The Auditors Cometh…
Internal Audits
• Operation, Quality, Safety, Training
• Materials, Maintenance, Spare Parts
External Audits
• Environmental
• Safety (People, Product, Community)
• Legal/Financial
Auditors ask three key questions:
1. “Do you have a procedure for that?”
2. “Are you following your procedure?”
3. “Can you prove it?”
Slide 12
Internal Audits
• Operation, Quality, Safety, Training
• Materials, Maintenance, Spare Parts
External Audits
• Environmental
• Safety (People, Product, Community)
• Legal/Financial
Auditors ask three key questions:
1. “Do you have a procedure for that?”
2. “Are you following your procedure?”
3. “Can you prove it?”
Solution: Workflow
ModelModel the Process – Create Processes, Forms, & Reports
ExecuteExecute the Process – Manage & Escalate Tasks, Coordinate Resources
AnalyzeAnalyze the Process - Find Bottlenecks, Get Alerts
ImproveImprove the Process – Continuous Improvement
Slide 13
ModelModel the Process – Create Processes, Forms, & Reports
ExecuteExecute the Process – Manage & Escalate Tasks, Coordinate Resources
AnalyzeAnalyze the Process - Find Bottlenecks, Get Alerts
ImproveImprove the Process – Continuous Improvement
Workflow: Criteria for Success
Access to the Right Information:
• Accurate
• Timely
• In Context to the Process
Take the Right Action at the Right Time:
• People
• Procedures
• Systems
– Process
– Plant
– Business
Slide 14
Access to the Right Information:
• Accurate
• Timely
• In Context to the Process
Take the Right Action at the Right Time:
• People
• Procedures
• Systems
– Process
– Plant
– Business
Complex Workflows• Transitions
– Inhibits the execution of a workflow until acondition is met
• Conditional Branching– Allows one branch of activities to execute
based on the evaluation of an expression
• Decision Branch– Executes one branch of activities if the
evaluation of an expression is true. Executesthe alternate branch if the evaluation is false.
• Loop– Executes a series of activities until a condition
is met.
• Queuing– Manages tasks efficiently
WF Trigger - Start
Look Up Product Codefrom Lot ID
Wait for CNC ProgramTo be downloaded
Standard SetupProcedure Verification
Verify ConsumablesAgainst BOM
CorrectConsumable
Materials
Wait fordownload to complete
Slide 15
• Transitions– Inhibits the execution of a workflow until a
condition is met
• Conditional Branching– Allows one branch of activities to execute
based on the evaluation of an expression
• Decision Branch– Executes one branch of activities if the
evaluation of an expression is true. Executesthe alternate branch if the evaluation is false.
• Loop– Executes a series of activities until a condition
is met.
• Queuing– Manages tasks efficiently
Issue the “START”Transaction
END
ConsumablesCorrect?
CorrectConsumable
Materials
NO
YES
SystemPlatform
Control/SCADA
Workflow Platform
Solution Focus
• One Window
• Intuitive Forms
• Human Workflows
• 100% browser based
• Integration withexisting applications
WonderwareWorkflow
SAP
IntelaTracMobile
Solutions
MicrosoftBizTalk
MicrosoftSharePoint2007/2010
InTouchHMI
Types of Workflows
• Application Specific
• Workflow PlatformSafety
MES
“Every Stakeholder thatneeds to be involved,gets involved”
Slide 16
Solution Focus
• One Window
• Intuitive Forms
• Human Workflows
• 100% browser based
• Integration withexisting applications
WonderwareWorkflow
IntelaTracMobile
Solutions
Model-basedTechnology
3rd PartyApplications
MicrosoftOffice
MicrosoftBizTalk
Outlook
Word
LIMSPLM
ROMeo
PIPEPHASE
OTS
“Every Stakeholder thatneeds to be involved,gets involved”
Wonderware System Platform is:Collection of software components that provides:• Data Acquisition, contextualization, and aggregation
• Supervisory Control
• Historization
• Visualization & Annunciation
• Reporting
• Unified Development Environment
• Extensible Container for Advanced Applications
Collection of software components that provides:• Data Acquisition, contextualization, and aggregation
• Supervisory Control
• Historization
• Visualization & Annunciation
• Reporting
• Unified Development Environment
• Extensible Container for Advanced Applications
Wonderware System Platform:Core Component Overview
Wonderware System Platform
Wonderware ClientsHistorian Client(Analysis Client)
Historian Client(Analysis Client)
Information Server(Web Reporting Client)Information Server
(Web Reporting Client)InTouch
(Visualization)InTouch
(Visualization)
Slide 19
Wonderware System Platform
Application ServerApplication Server HistorianHistorianInformation
ServerInformation
Server
Device Integration ProductsDevice Integration Products
3rd PartyData
Sources
3rd PartyData
SourcesSoftware
ApplicationsSoftware
Applications3rd Party
Controllers3rd Party
Controllers
One Platform for Enterprise Control
Supervisory Control
Enterprise Service BusEnterprise Service Bus
Business Transactions
Functions
Historian
SupervisoryControl
Application Models
- Plant Model
- Templates
- Standards
- Operations
- Security
- Intelligence
Common Services
- Global Naming
- Security
- Manage/Deploy
- Messaging
- Alarm\Events
- High Availability
PresentationHMI
Web ProductionMES
PerformanceOEE
Enterprise Integration
Device Integration Service BusDevice Integration Service Bus
Time Series Data
Field Devices
System PlatformSystem PlatformHistorian
Application Models
- Plant Model
- Templates
- Standards
- Operations
- Security
- Intelligence
Common Services
- Global Naming
- Security
- Manage/Deploy
- Messaging
- Alarm\Events
- High Availability
Web
Device Integration
Analyze
Report
ProductionMES
MaintenanceCBM
Energy MgmtCEM
WorkflowBPM
IntelligenceEMI
Wonderware Workflow Components
Wonderware Workflow Software
EnterpriseConsole
BizTalkConnector
SharePointConnectorSharePointConnector
SystemPlatform
Connector
SystemPlatform
Connector
IntelaTracConnector
InformationServer
Connector
InformationServer
Connector
Slide 21
BAM Reports
FormDesigner
ProcessDesigner
BizTalkConnector
BizTalkConnector
SharePointConnector
SAPConnector
SAPConnector
SystemPlatform
Connector
MESConnector
MESConnector
IntelaTracConnectorIntelaTracConnector
HistorianConnectorHistorianConnector
InformationServer
Connector
InformationServer
Connector
OPC UAClient
Connector
OPC UAClient
Connector
System Platform ConnectorComponentsAutomation Object
• $WorkflowGateway Object
Script Function Library
• Workflow Toolbox
• Workflows Tab
.NET Controls
• BAM
• Fill Form
• Inbox
• List Form
• List View
• Workflow Status
Slide 22
Automation Object
• $WorkflowGateway Object
Script Function Library
• Workflow Toolbox
• Workflows Tab
.NET Controls
• BAM
• Fill Form
• Inbox
• List Form
• List View
• Workflow Status
Example: Hazardous Spill Response
Issue Identified byConveyor Monitoring system
Kevin opens his inbox andfills the form with relevantinformation and submits
the form . (System ensuresinformation is complete)
Did Kevintake action?
Workflow is triggered
Yes No
No
SupervisorApprovalreceived
Supervisor is notified toreview the form submittedby Kevin and approve as
appropriate
InTouch Screen(Action Needed)
Slide 29
Escalation sent to Kevinand Supervisor is Alerted
Workflow Ends
Yes
App Server updated withcontextual information and
Documents are posted to complyto legal regulations
App Server updated withcontextual information and
Documents are posted to complyto legal regulations
Yes
SupervisorApprovalreceived
Supervisor is notified toreview the form submittedby Kevin and approve as
appropriate
Example: Lockout / Tagout Process
LockoutTag
Required
Yes
No
Notification to affectedemployees indicating
maintenance.
Visible in SC
AD
A display
Issue Identified byControl System
or Operator
Notify Maintenance /Servicing Crew
Slide 35
Completed notificationsent to supervisor and
affected employees
Machine Shutdownand lockout tags
implemented
Restore MachineTag update
Visible in SC
AD
A display
Perform Maintenance
WorkflowEnds
Example: Energy Peak Demand Avoidance
Monitor the Real-time DemandDetect impending deviation
Notifications are sent tothose who will be impactedby a load shedding event.
Kevin has to explicitlyauthorize halting further
production to avoiddemand charges
Did Kevintake
action?
Workflow is triggered
Yes NoLead Ackreceived
Production Leads arenotified to not start neworders and put current
orders on hold
Supervisor Screen(Action Needed)
Slide 36
Escalation sent toPlant Manager
HR Alerted
Workflow Ends
Yes
Audit trail is updated with allactions and a snapshot of current
energy demand is captured.
Audit trail is updated with allactions and a snapshot of current
energy demand is captured.
Yes
Lead Ackreceived
Production Leads arenotified to not start neworders and put current
orders on hold
Online MonitoringSystem
SCADA detects‘Main Break’
No
Close Valve forFaulty Line
Activate alternateflow
Notify Lab Personnel
Notify PolicePersonnel
Notify UtilityMaintenance Crew
Collaborationwith Lab
Check forcontamination
YesCompare withthe permissible
standards
Normal
Complex Example: Pipeline Break
Slide 37
Implement ‘Boil Water’Ordinance
FlushPipeline
Initiate ConsequenceManagement Plan
Lift the ordinance
Yes
No
Repair pipeline
Check forcontamination
Check forcontamination
YesCompare withthe permissible
standards
High
Normal
High
Normal
Compare withthe permissible
standards
Beyond Automation:Workflow Examples
• Energy: Peak/Demand Response
• Quality: HACCP, Recall, Sampling/Testing
• Safety: LOTO, Hot Work Permit, Confined Space Entry
• Operations: Training, Execution, Exceptions, Alarms, Cleaning
• Maintenance: Shutdown, Repair/Replace, Startup, Auto W.O.
• Engineering: Plant Shutdown/Startup, Critical Asset Procedures
• R&D: New Product Development & Testing
• Supply Chain: Inventory Reconciliation, Materials Staging
Slide 40
• Energy: Peak/Demand Response
• Quality: HACCP, Recall, Sampling/Testing
• Safety: LOTO, Hot Work Permit, Confined Space Entry
• Operations: Training, Execution, Exceptions, Alarms, Cleaning
• Maintenance: Shutdown, Repair/Replace, Startup, Auto W.O.
• Engineering: Plant Shutdown/Startup, Critical Asset Procedures
• R&D: New Product Development & Testing
• Supply Chain: Inventory Reconciliation, Materials Staging
Real-World ChallengesReal-World Opportunity!
Many Data Sources:• ERP
– Orders/Finished Goods
– Raw Materials
• Quality/LIMS
• Ops Management– Process Specifications
– Consume/Produce/WIP
– Asset Performance/OEE
– Historian
• Maintenance EAM/CMMS
Many Roles:• Operations
• Maintenance
• Quality
• Safety
• Environmental
• Supply Chain
• Finance
• Corporate
Many Systems:• Enterprise Applications
– ERP, EAM/CMMS, Custom DB
• Automation Applications– PLC, DCS, HMI, SCADA, MES
• Desktop Applications– Word, Excel, Outlook, Visio
• Web-Based– Custom Portal, SharePoint
• Manual – HumanDecision– Voice, Text, Email
Slide 41
Many Data Sources:• ERP
– Orders/Finished Goods
– Raw Materials
• Quality/LIMS
• Ops Management– Process Specifications
– Consume/Produce/WIP
– Asset Performance/OEE
– Historian
• Maintenance EAM/CMMS
Many Roles:• Operations
• Maintenance
• Quality
• Safety
• Environmental
• Supply Chain
• Finance
• Corporate
Many Systems:• Enterprise Applications
– ERP, EAM/CMMS, Custom DB
• Automation Applications– PLC, DCS, HMI, SCADA, MES
• Desktop Applications– Word, Excel, Outlook, Visio
• Web-Based– Custom Portal, SharePoint
• Manual – HumanDecision– Voice, Text, Email
Highlights: Wonderware Workflow 2012
Business Value
• Enable Operational Improvements
• Improve Procedural Quality, Consistency
• Adhere to and enforce Regulatory Compliance
Key Capabilities
• Digitally Capture, Institutionalize BestPractices
• Preconfigured Workflows
• Business to Mfg. Connectivity(human-centered)
Slide 42
Business Value
• Enable Operational Improvements
• Improve Procedural Quality, Consistency
• Adhere to and enforce Regulatory Compliance
Key Capabilities
• Digitally Capture, Institutionalize BestPractices
• Preconfigured Workflows
• Business to Mfg. Connectivity(human-centered)
Architecture / Topology
Workflow EngineTask Scheduler
Communication Service
Workflow EngineTask Scheduler
Communication Service
Central Configuration Site locationEnterprise Console informationGlobal configuration settings
Central Configuration Site locationEnterprise Console informationGlobal configuration settings Repositories
Central Configuration SiteEnterprise Console
Central Configuration SiteEnterprise Console
SkeltaServer 1
SkeltaServer n
SkeltaFarm DB
SkeltaClient 1
SkeltaClient n
SkeltaDatasource 1
SkeltaDatasource n
Slide 44
Workflow EngineTask Scheduler
Communication Service
Workflow EngineTask Scheduler
Communication Service
Central Configuration Site locationEnterprise Console informationGlobal configuration settings
Central Configuration Site locationEnterprise Console informationGlobal configuration settings RepositoriesRepositories
Central Configuration SiteEnterprise Console
Central Configuration SiteEnterprise Console
Farm DBFarm DB
Datasource 1Datasource 1 Datasource nDatasource n
Repository 1 Repository n
Wonderware Workflow SoftwareSkelta BPM.NET ArchitectureSkelta Server Controls can be reused and embeddedin a custom ASP.NET application. These same controlsare used in Skelta Enterprise Console, the ArchestrAIDE and ArchestrA Graphics.
Skelta Enterprise Console is a web-based interfacethat allows authorized users to build workflow drivenapplications and also allows users to participate inthese applications.Skelta Repository contains workflow definitions,
queues, calendars, settings, workflow execution dataand Business Activity Monitoring (BAM) data.
Forms Engine is responsible for every activity starting fromthe time a form is opened till a form is closed. It captures all thereal-time user inputs, processes the inputs and displays thisinformation in terms of controls, business logic and usability.
The Integration Layer acts as aninterface between Skelta BPM.NETand third-party applications.
Supports the following Security &Directory Services:1.) Active Directory2.) Lightweight Directory Access
Protocol (LDAP)4.) Any User Directory5.) .NET Role Provider6.) ArchestrA Security
Delivery Channels are interfaces for users to interact withworkflows. Skelta BPM.NET provides multiple deliverychannels which include: Browser, Messenger Services, MobilePhones, Email, MS Outlook, Desktop Applications.
The Skelta Services comprise: Workflow Engine Services,Task Scheduler Services, Skelta Communication Services,Skelta Advanced Server Service.
Web Services - Skelta BPM.NETprovides out-of-the-box activities thatcan be used to call a third-party WebService from a workflow.
Skelta Object Access allows reuse of third-party .NET objects. Allows registration ofthird-party object assemblies.
The Enterprise Event Bus handles third-partyevents that trigger a workflows. The third-partyevents can include updating SharePoint lists,updating files and receiving e-mails.
Microsoft Integration - SkeltaBPM.NET integrates with thefollowing Microsoft applications:1.) Exchange2.) SharePoint3.) Word4.) InfoPath5.) SQL6.) BizTalk7.) Visio