Transcript Routes for Integrating Auto-ID Systems into Manufacturing

Real-time Manufacturing Control
2005. 5. 27
Noh, hyun-il
Routes for Integrating Auto-ID Systems
into
Manufacturing Control Middleware
Environments
White paper p1~28, 2003 AUTO-ID CENTRE
Nirv chokshi, Alan Thorne, Duncan McFarlane
Contents
Introduction
Manufacturing Control Middleware
Requirements for Integrating Auto-ID
Infrastructure within Manufacturing Control
Different Routes for Auto-ID Integration
A Recommended Procedure for Auto-ID
Integrated Control Design
Conclusion
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1. Introduction(1/2)
Background
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Facility of instance level product information in Auto-ID will
lead to a multi-fold increase in the amount of data to be
processed in real time.
How to handle such data effectively and economically will
be crucial in developing the technology itself.
Modern industrial database systems have become
increasingly sophisticated and easy-to-use for storing and
retrieving large amounts of real-time, time-consistent
information
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1. Introduction(2/2)
Aims of the Paper
 Set of applications managing the interface
between real-time sensory data and business
information as “middleware”

The three principle aims of our analysis
Review the existing use of automatic identification
techniques by understanding the operations of
dominant control system
Examine the capability of such systems for dealing with
Auto-ID information
Proposed and analysis different routes through which
Auto-ID infrastructure
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2. Manufacturing Control Middleware
Focus of paper
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2. Manufacturing Control Middleware
MESA model
Monitoring the progress
Guiding what people,
of units, batches, or
machines,
lots
tools and
of outputMonitoring,
to create
material
agathering,
full should do, and
history ofand
theorganizing
product
trackingdata
what they are
doing or have
about thecurrently
progresses,
just done
material, and operations
from people, machines or
controls
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2. Manufacturing Control Middleware
Recently, automation vendors have their own MES
solution link with their real-time control product
Dominant Commercial Products
and Their Trends of Development
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Integrated MES Suites
( Factory Suite, Factory Talk, Simatic IT framework)
Acceptance of Product and Process Description standards
( ISA-S95, ISA-S88, IEC-1131)
Integration of Business, Execution and Real-time
Control levels
( Vertical integration of MES solutions with ERP)
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2. Manufacturing Control Middleware
Use of Product Identity Information in
Manufacturing Control (overview)
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Product Tracking and Genealogy
Automated Storage and Retrieval (AS/RS)
Product Routing, Dispatching and Flow Control
Process Recipe Management
Forecasting of raw-material consumption, statistical
process control, estimation of resource usage
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2. Manufacturing Control Middleware
Previous Use of Automatic Identification in
Manufacturing Control
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Discrete Sensing : Presence of product location
Bar-codes : Tracking of product on conveyors
Identifying raw-material
Assessing work-in-process inventory
RFID : Tracking aggregates pallet or unit load
Ease of managing AS/RS systems
Storing machining instructions on tags to ensure
consistency between different machining stations
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2. Manufacturing Control Middleware
RFID tags in real-time control of sorting conveyor
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3.Requirements for Integrating AUTO-ID
Infrastructure Manufacturing Control
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3.Requirements for Integrating AUTO-ID
Infrastructure Manufacturing Control
Software/Hardware Development Perspective
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Ease of development and use
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Speed of response
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Reliability, Fault-tolerance and the Deterministic Character
of Operation
Distributability of Software/Hardware Modules
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3.Requirements for Integrating AUTO-ID
Infrastructure Manufacturing Control
Data Management Perspective
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3.Requirements for Integrating AUTO-ID
Infrastructure Manufacturing Control
Data Management Perspective

Optimality of Information Pattern
Tag Data Filtering Early in the Information Channel
Pull vs. Push type Data Delivery Mechanisms
Use of Tags with Memory
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3.Requirements for Integrating AUTO-ID
Infrastructure Manufacturing Control
Data Management Perspective
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Distributed Data Management
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3. Integrating AUTO-ID
Infrastructure Manufacturing Control
Data Management Perspective
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Real-time Data Storage and Retrieval Procedure
Temporal database management
: deal with information containing timestamps
Real time database management
: timing constraints associated with database operations
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4. Different Routes for Auto-ID
Integration
Horizontal Distribution of Savant™ Functionality

Approach1 : Centralized Plant-wide Design of Savant™
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4. Different Routes for Auto-ID
Integration
Horizontal Distribution of Savant™ Functionality
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Approach2 : Cell-level Distribution of Savant™
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4. Different Routes for Auto-ID
Integration
Horizontal Distribution of Savant™ Functionality
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Approach3.1 :Machine-level Distribution of Savant™
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4. Different Routes for Auto-ID
Integration
Horizontal Distribution of Savant™ Functionality
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Approach3.2 :Integration of Savant™ within PLCs Exiting
Data Management Tools
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4. Different Routes for Auto-ID
Integration
Vertical Distribution of Savant™ Functionality

Approach4 :Integration of Auto-ID Information at Business
Management Level
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4. Different Routes for Auto-ID
Integration
Vertical Distribution of Savant™ Functionality
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Approach5 :Hierarchical Distribution of Savant
Functionality
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4. Different Routes for Auto-ID
Integration
Vertical Distribution of Savant™ Functionality
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Approach6 :Direct Integration of Vertically Distributed
Savant™ Components within Control Hierarchy
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5. A Recommended Procedure for
Auto-ID Integrated Control Design
Perform a Use-case Analysis for identifying
Analysis quantify the benefits b overlooking the impact of
new technology on existing procedures
( labor saving, hardware/software costs, business profits)
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Define control logic for Auto-ID integrated
operation
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Identify closed-loop information pattern
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5. A Recommended Procedure for
Auto-ID Integrated Control Design
Categorize plant locations from where the product
identity information could be acquired
Each location may have different frequency( read rate ),
read range, aggregation requirements
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Define the overall information channel
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Identify an abstract architecture of how information will
flow in the network
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5. A Recommended Procedure for
Auto-ID Integrated Control Design
Define reader network design
Identify the locations for placement of readers
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Define basic and extend Savant™ operations
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Distributed considering legacy systems, fault tolerance,
hardware/software availability, amount of data process
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5. A Recommended Procedure for
Auto-ID Integrated Control Design
Define the information channel for network PML
integration in control decisions
The link may be both outward (storing new product) as
well as inward (receiving process recipe information)
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Analyze / Optimize Information Channel
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Develop different use-case defining the ways in which
basic Auto-ID components could be placed within
channel
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5. A Recommended Procedure for
Auto-ID Integrated Control Design
Analysis different routes in which Information
Channel could be optimized
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Seeking to distribute of Extended Savant™ module to
provide information decentralization
Transferring filtering functionality directly to the location
where excess
Consider the option of Tags memory
Deciding between Push vs. Pull mode of information
channel ( where the information is needed and would
send such directly to specification)
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6. Conclusion
Auto-ID information generate a vase amount of
real-time data( need efficiency process )
Requirement for integration by 2 perspective
Set of potential routes in which this integration can
be performed
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Horizontal & vertical distribution of Savant™ functionality
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