www.mesa.org2008 North American Plant-to-Enterprise ConferenceSeptember 21-23, Orlando, FL

SOA in ManufacturingA Panel Discussion

Dave Noller Tim Thomasma Charlie Gifford

Mike Brooks Bryan Zigler

Strategic Initiatives

The following Strategic Initiatives of MESA International are associated with

this presentation: *

Lean ManufacturingQuality & Regulatory Compliance

Product Lifecycle Management (PLM)Real-Time Enterprise

Asset Performance Management (APM)* SOA is a horizontal technology and applies to all of these

Discussion Agenda

• Business issues driving change • Architecture and standards• Case Studies:

– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron

Discussion Agenda

• Business issues driving change • Architecture and standards• Case Studies:

– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron

• Lack of flexibility• Obsolete technology• Lack of system commonality across company

• High support costs• Evolving business models

Broadcast

WIPTrack

ProductionMonitoring

Scheduling

SCADA

ANDON

DataCollection

ReSequence

eKanban

Logistics

Suppliers

CorpSystems

OrderMgmt

Quality

ErrorProofing

AssetMgmt.

Requirements for Agility Are Forcing Change

• Poor asset utilization• Multitude of point to point integrations

• Various operating systems and languages

• Many device connections

Discussion Agenda

• Business issues driving change• Architecture and standards• Case Studies:

– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron

“Mfg 2.0” Defines the Need for “MES by Composition”

Source: Manufacturing 2.0: Service and Collaboration-Based Architectures for Manufacturing Right First Time—on demand AMR Research, 2007

AMR Research Manufacturing Exchange © 2007 AMR Research, Inc. | Page 8

EWIEWIQualityLIMSQuality

LIMSODSODS

MES

Manufacturing SOA: Foundation for Manufacturing 2.0

DBLogic

UI

MfgMDM

Security and Management

ODS EnterpriseApps

QualityLIMS EWI

Event/ActivityMonitoringOPM OI Ops

PortalMfg

ContentMfg Service

Registry

Transact Enrich Manage

Service Enablement Layer

MES ProductsAssets

ProcessesEtc.

DCS, PLC, RFID (OPC), Wireless Sensors

MES

Services Bus

Manufacturing Composite Apps

ScheduleOptimization

Track &Trace

RightFirst Time MES 2.0

Office Web 2.0

Asset Performance

Recipe Workbench

Governance

Tools (e.g., MC

E)

MCE = Manufacturing Composition Environment, OPM = Operations Process Management, OI = Operations Intelligence,LIMS = Laboratory Information Management System, EWI = Electronic Work Instructions AMR Research 2007

Standards Model for Manufacturing Solutions

• SOA provides a common framework for integration SOA is assisted by content standards, providing a common set of semantics / data content for integration

• OAGi, ISA-95, AIAG, STAR , JAMA, ODETTE….

• Standards groups including OAGi, ISA, OPC Foundation, Mimosa and WBF have been working to map and converge some of the existing standards (initial focus on OAGIS and ISA-95). This work is now sponsored by the OpenO&M group. OAGIS 9.2 includes results from this work.

Modeling (e.g. based on ISA-95) Adds Structure and Supports Data Exchange

Between Disparate Architectures

Firewall

Device Communications

Plant Communications Legacy Technologies (Sockets)TCP/IP – LAN

WS-I Compliant Web Services

Guaranteed DeliveryPub-SubSerial

EthernetOPC

InternetANX – Secure Channel Internet

SSL/Encrypted MessagingWS-I Compliant Web Services

Enterprise CommunicationsTCP/IP – WAN

WS-I Compliant Web ServicesBehind corporate firewall

Supply Chain Environment

Shop Floor

Plant Computer RoomOffice Automation

Enterprise Data CenterInternal Facing

ExtranetEnterprise Data Center

External Facing

Firewall

Firewall

InternetDMZ

ManufacturingSystems

PlantSystems

EnterpriseSystems

Middleware

EdgeComponents

Middleware

ISA Levels 0, 1, 2

ISA Level 3

ISA Level 4

Modeling(Transactions)

Modeling

Discussion Agenda

• Business issues driving change • Architecture and standards• Case Studies:

– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron

eHub at Ford – 2001 Initial Production Environment

eHub Production Environment

HPUXHPUX1a

Browser

Server

Plant

W2KW2K

NT 4 SP4NT 4 SP4

1a

1a

IIS BTS

4-Way

1b

Data Center DMZ Supplier

IIS,SOAPIIS,

SOAP

21a: Event to initiate trans (HTTP Post)

1b: Event to initiate BTS (ASP Submit)

1c: Store trans for later access/analysis2: Provide supplier access to trans

IIS BTS

4-Way

1b

Cisc

o Lo

cal D

irect

orC

isco

Loca

l Dire

ctor

SQL ClientSQL Client

SQL ClientSQL Client

Connect to IIS/BTS via HTTP

3

4. Allow supplier to set communication criteria

4

BTS = BizTalk ServerSOAP = Simple Object Access ProtocolIIS = Internet Information ServerOAG = Open Applications GroupBOD = Business Object Document

OAG BOD

OAGBOD

OAG BOD

2 load balanced 2-Ways

3: Push trans to supplier

firewall

4-Way, clustered (Active/Active)

DB instances:BTS1 BTS2

eSMART eQLS ePOSmon…

1c

4-Way, clustered (Active/Active)

DB instances:BTS1 BTS2

eSMART eQLS ePOSmon…

1c

Discussion Agenda

• Business issues driving change • Architecture and standards• Case Studies:

– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron

SOA has Allowed IBM to Create a Virtual Manufacturing

Enterprise….

• The various permutations and combinations carry with them many requirements for successful integration:

– pathways between all participants must be reliable and secure

– IBM must see all events as they occur

– IBM must collect all data as it is produced, at any source

– each participant must accept control from IBM sufficient for consistent product & process results

– each participant must have access to all necessary functions, even if not local/native to their environment

– pathways between participants must be dynamically flexible and possible to select in real-time via business rules

WaferFab

WaferTest

ModuleBuild

ModuleTest

IBM 200mm IBM 200mm IBM A IBM A

IBM 300mm IBM 300mm IBM B IBM B

Vendor A Vendor B Vendor C IBM C

Vendor C Vendor D Vendor C

Vendor E

Vendor F

Primary PathAlternate Path

ILLUSTRATIVE SCENARIO

where ‘Virtual’ means….

1.Standard integration of one or more heterogeneous mfg assets/systems

2.Convergence of all mfg assets/systems to a single interface to/from enterprise systems

3.Aggregation of data from all mfg assets to a single standard and integrated form

4.Management control of all mfg assets in real-time, defining control points, parameters and rules to enact in order to meet product requirements

SUPPLIER

VENDOR(S)

MES BACKBONE

CUSTOMER 1 CUSTOMER 2 CUSTOMER N

Fulfillment &Distribution

Supply/DemandPlanning

Finance &Costing

Data Warehouse &eBusiness

SupplierProductionMES/Asset

VendorProduction

MES/Asset 1

VendorProduction

MES/Asset N

2

134

MDI11

SUPPLIER

VENDOR(S)

MES BACKBONE

CUSTOMER 1 CUSTOMER 2 CUSTOMER NCUSTOMER 1 CUSTOMER 2 CUSTOMER N

Fulfillment &Distribution

Supply/DemandPlanning

Finance &Costing

Data Warehouse &eBusiness

SupplierProductionMES/Asset

VendorProduction

MES/Asset 1

VendorProduction

MES/Asset N

2

134

MDI11

(IBM)

Enterprise Systems

Mfg S

ite/Vendor S

ystems

Order Management WIP Tracking Broadcast - Print Broadcast - Device B2B Business System Interface Parts Verification Parts Traceability Parts Containment Record Defects Record Repairs Final Finish

Enterprise Services Bus

Wireless Business Systems End User Portals Suppliers .

Industry workbenches allow services to be quickly configured by production personnelinto a process workflow to support workstation logic

Manufacturing Services Pallet

Service Service Service Service

Service AdapterService

Process

Workflow

Services

Station LogicWorkflow

BPEL

Production Database

PLC

Services

Process Location 1

Automotive Assembly Example

PLC

Services

Process Location 2

Device Gateway Device Gateway

2findOrderupdateWIPStatusupdateLegacybroadcastOrder

New services, legacy

wrappers, orMES COTS

WIP Tracking Event

1Broadcast Order Data to device(s)

3

WIP Tracking Event

4

findOrderupdateWIPStatusupdateLegacybroadcastOrder

New services, legacy

wrappers, orMES COTS5

Broadcast Order Data to device(s)

6

Discussion Agenda

• Business issues driving change • Architecture and standards• Case Studies:

– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron

Semantic Layer is SOA Business Case

• Interoperability requires interfaces to be standardized. Only 5% of the interface is a function of the middleware.

• The other 95% is a function of the application semantics. (Gartner Group)

Application Integration Semantics

Messaging and Transport Services

95%

5%

OAGIS

Level 3: Manufacturing Operations

Level 4+: Enterprise

Level 5+: Inter-Enterprise

Levels 2, 1, 0: Machine / Plant Work

OPC: DA, HDA, A&EOMAC

Discrete Process

OAGIS

MIM

OSA

ISA-99

OPC

UA ISA-95

ISA-88B2MMLOAGIS

The Integration Evolution: OpenO&M™ Domain Map

F O U N D A T I O N

Hybrid

Let’s Talk about B2M Business Value

Open O&M Technical Applications and Methods being applied by Innovative Manufacturers, Vendors, and SIs

• 3M, Genentech, Kraft, FritoLay, GM, Tata Motors, Dow, DuPont, P&G, Pfizer, BP, Nestle, Masterfoods, BP, Chevron, Coors-Molson, Eli Lilly, InBev, Wrigley, Heineken, Lion Nathan, GE Health, J&J, SAB Miller, others

• Oracle, SAP, IBM, Tibco, Infor, others

• GE Fanuc, Rockwell, Wonderware/Invensys, ABB, Siemens, Honeywell, Citect, Werum, AspenTech, Kepware, others

• Atos Origin, Logica CMG, Ordina, EDS, AAG companies, Wipro, Maverick Technologies, Entegreat, ASECO, NNE Pharma, Wunderlich-Malec, others

Copyright @2007 AMR Research: All rights reserved.

Revenue Share Growth Opportunities: Emerging Economies

Top Revenue Producing Regions: 07 & 12

Capacity Realignment: Proximity to New Markets

Top Mfg./Sourcing Regions: 2007 & 2012

Copyright @2007 AMR Research: All rights reserved.

► We expected ONE-TO-MANY

PI-PCS ……SAP XI

SAP R/3 MM – PP-PI – QM

MESSystem X

Plant A,B,C ..

MESSystem Y

Plant M,N,..

MESSystem ..Plant ..

PLC PCSPLCPLC PLC

ISA-95/WBF standard (B2MML XML)

PCS PMYPPPSAP xMII

MESSystem X

Plant A,B,C ..

MESSystem Y

Plant M,N,..

MESSystem ..Plant ..

PLC PCSPLCPLC PLC

ISA-95/WBF standard (B2MML XML)

Site XSite X

Site XSite X

► It was more like MANY-TO-ONE(-to-many..)

ArlaTemplate

#1

ArlaTemplate

#2

ArlaTemplate

#3

Arla Foods: Motivation to use Open Standard Integration!

The Arla Food Costs ?Site 1 to 15

2003-2006 2007 2008

Specification

R/3 -config

MES-config

Testing +go-live

24x7

XI-config24x7

Specification

R/3 -config

MES-configTesting +

go-live

24x7

xMII-config24x7

R/3 -config

MES-configTesting +go-live

24x7

xMII-config24x7

Specification

Expensive ?? YES, integration is still complex and both procedures & structure is needed !!!

SOAEvolution

Message Queuing

Abstracts the connectivity

logic from the application

Message Brokering

Abstracts the connectivity + mediation logic from the application

Service Orientation

Reduces application to its core business

functions(i.e. a service)

Application Application

Degree of Flexibility and Reuse

Direct Connectivity

All connectivity, mediation and additional logic (e.g. conditional processing, routing) buried in the

application.

Application

Line

s of c

ode

Application Services

Mediation &additional logic

Additional Logic

Connectivity logic

Connectivity andmediation logic

Connectivity,mediation &

additional logic

Connectivity,mediation &

additional logic

Discussion Agenda

• Business issues driving change • Architecture and standards• Case Studies:

– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron

Boeing Vision “Design Anywhere, Build Anywhere”

BOEINGFACTORY

BOEINGFACTORY

Enable Lean Interoperability betweenDesign and Execution

BOEINGFACTORY

BOEINGFACTORY

SUPPLIERPORTALBPN

Sort – Process Modeling– Sort business processes and activities operate value streams

• Simplify – Common Processes– Simplify things and derive potential services– Eliminate unnecessary complexity across the value stream

• Sweep – Identify Services– Derive patterns, models to help with solution

• Standardize – Standard Service Definition – Define, declare standard services– Register them, apply governance

• Self-Discipline – SOA Leaning Curve– Cultural/knowledge transfer– Indoctrinate people (change the mind set)

SOA+ is consistent with 5S(Foundation for Lean)

Just-In-Time Binding Example

MES 1

UDDI Service

AdapterService

AdapterService

1. Services are indexed in UDDI

2. Create Order step retrieves binding information from UDDI

3. Create Order step uses appropriate Service to complete business process

ReceiveDemandTrigger

GetPlanning

Data

CreateOrder

Enterprise Service Bus

MES 2

Discussion Agenda

• Business issues driving change • Architecture and standards• Case Studies:

– Ford eHub– IBM Semiconductor– Open O&M Adaption– Lean Manufacturing at Boeing– “Next Generation” at Chevron

Refining: people & work processes

SOA Opportunity?

we need a software 

framework that helps 

improve the performance 

of all personnel across all 

Chevron refineries

must do for production management…

what SAP does for business & 

what Yokogawa does for operations

Current

reliability

maintenance

control Supply & distribution

accounting

planning

trading

management

lab

good enough in the past

marketing

A New Architecture

Required Foundation

3636

12

The Approach

lead the industry, drive COTS

standards… liberate us…help them deliver what we need

push hard for services maturitythat exceeds current offerings