SIMATIC IT for Discrete Industry Mechatronics Assembly Line V2.3 SP1

Transcription

1 SIMATIC IT for Discrete Industry Mechatronics Assembly Line V2.3 SP1 Functional Overview February 2015

2 2 Contents 1 Introduction MES and Production Modeling Standards and Compliance ISA-95 Compliance Why focus on MES and Production Modeling? Business issues Production issues IT issues How you can succeed The SIMATIC IT model for Discrete Industry Business Benefits Production Benefits IT Benefits SIMATIC IT Industry Libraries Discrete for Mechatronics Assembly Line Traceability Defect Logging Interlocking Reporting Communication Major features in version 2.3 SP What s New in SIMATIC IT for Discrete Industry Mechatronics Assembly Line v 2.3 SP

3 3 1 Introduction 1.1 MES and Production Modeling In the early Nineties, industries acknowledged the need for a layer to integrate and link Business Systems with Control Systems. The term Manufacturing Execution Systems (MES) has been used from the start to specify all those functions and products that satisfy this need. Initially, MES indicated a gray area that was a hodgepodge of almost every application or product that could not be clearly assigned to either the Business System or the Control System layer. Most of these products were spinoffs of applications developed by a System Integrator for a particular Customer and were generally focused on a very specific area (i.e. scheduling, laboratory, quality, tracking ). After some time, international organizations addressed the need for a clearer definition of MES: MESA (Manufacturing Enterprise Solutions Association) and, as a consequence, ISA (Instrumentation System and Automation Society) later developed models that describe these levels and seek to standardize them. Under the pressure of new business-driving forces that have been emerging in recent decades, Manufacturing Plants continue to play a major role. The globalization of both companies and production processes makes it necessary to create new models. Manufacturing is not a process that can be completed by a single self-enclosed entity, but extends beyond the bounds of the Plant, the Country and the Enterprise. Therefore, MES cannot act simply as an interface between Business and Process layers, but requires a substantial number of functions that are crucial to a Company s success. Rather than remaining distinct from one another, connected solely by a data exchange layer, these functions need to be coordinated, in adherence to the Business and Production strategy. ISA-95 documents point this out very clearly, describing the MES process in terms of both data and interaction between functions (e.g. Order Dispatching, Resource Management). The result is a new approach to MES, based on an architecture that allows describing Business Processes that orchestrate functionalities provided by a set of specialized and affordable Components. At the same time, this orchestration must also involve the Automation and Control level, thereby making both MES and Control part of the same Collaborative Production Management system.

4 4 1.2 Standards and Compliance ISA-95 Compliance ISA-95 is acknowledged as the most authoritative standard for MES applications. Not only Market Analysts such as AMR ( and ARC ( confirm this, but also several major vendors adopt this standard. In addition to Siemens, we can find, for example, SAP and Microsoft. Siemens works in close conjunction with ISA and was the very first MES vendor to offer a comprehensive product implementing the ISA-95 standard. This translates into standardized terminology, concepts and models for integrating manufacturing operations functions with enterprise functions. Such standardization is achieved with ISA-95, which defines the functional view of an enterprise, allowing a simple generic model of work activities to be applied to the main areas of manufacturing. As a member of the ISA-95 Committee, Siemens actively contributes to the further development of this standard. Complying with ISA-95 makes it possible to reap some important benefits: in particular, for what concerns defining the hierarchical model of the MES solution, which simplifies developing solutions that are both standard yet flexible, while still satisfying customer requirements in full.

5 5 2 Why focus on MES and Production Modeling? On a daily basis, a variety of figures in charge of different activities face problems that involve manufacturing systems. Implementing MES and deploying the right production model can provide a solution to many of these issues. In broad outline, the problems encountered concern: S Business Production IT 2.1 Business issues Do you want to increase the overall efficiency of your supply chain? Supply-chain efficiency is strongly affected by how the Business Level (ERP) and the Shop Floor (Control) interact. MES represents the go-between, which, when streamlined and efficient, contributes to a better Supply Chain. Is your system able to react quickly to new conditions and new market requirements? In today s world of manufacturing, the ability to adapt to new operational requirements (i.e. changes in product specifications, quality procedures ) and environmental conditions (i.e. introduction of new standards ) is paramount to success. If your system is ready to meet these challenges, the reward may be a significant increase in your competitiveness, as well as impressive savings in terms of costs. Is your production process standardized across all plants? Guaranteeing uniform, consistent production procedures is a key issue in today's business. If this is lacking, then the result may be uneven quality of your product from one facility to another. Control System and Business System cannot solve the problem, as a structured and modeled environment is required in order to seamlessly coordinate the production process, also in different contexts (e.g. different hardware and software installation bases). Are you ready for new regulations? Some established standards and regulations, such as ISO, VDA, already exist to guarantee high-quality products. However, new regulations, as well as the need for exhaustive material traceability, are affecting manufacturing procedures substantially. MES can help you achieve compliancy with these regulations and maintain full accountability of materials. Would you like your business to be more customer-oriented? Standard monolithic applications often represent a barrier to implementing an efficient system that can adapt and satisfy ever-changing requirements from both the customer and the market. In view of the growing demands posed by customers, MES can make your system much more flexible and adaptable.

6 6 2.2 Production issues Do you handle reworks and scraps properly? Do you track how your materials are used with precision? Typically, reworks and scraps cannot be handled by control systems. Without appropriate management, excessive waste or uncontrolled material tracking can also affect the quality of your final product. In addition, overall material tracking throughout the production process is now a crucial factor for both accounting and the correct evaluation of production costs. S Do you need to increase visibility of your production process? Is your system able to provide Production-related KPIs and advanced reporting? To fully comprehend how your plant is performing, you need a system that can generate production reporting correlating process-control specific data with production-related data (i.e. order number, lots, personnel, materials ) to facilitate troubleshooting and analyzing performance problems. MES can heighten visibility in the production process, creating the right conditions to promote improvement and increase your manufacturing system s efficiency. Do you need to raise your level of quality? Are you able to pinpoint defective lots or out-of-spec finished-goods lots? Are you able to backtrack your production with accuracy? If not, you might be unable to address specific issues regarding the quality of your product. You may also be unable to respond to customer complaints appropriately or organize product recalls promptly. An efficient MES system can provide complete genealogy, being able to track materials throughout the entire production process. It also follows all material transformations with precision until the final product is produced and delivered to the final customer. Does your system react efficiently to production problems? Do you re-schedule your plant activities properly? What if something goes wrong on the shop floor? Efficient management of failures and downtimes is a must. Often, several systems need to be involved in order to solve the problem (maintenance must be informed, rescheduling is necessary; certain people must be notified as soon as possible ). Poor coordination leads to using resources in an ineffective manner, ultimately raising your production costs. Is your ERP System working with the Manufacturing Execution System efficiently? To optimize Supply Chain efficiency, the Business Logistic System must be informed in real-time as to what is happening on the Shop Floor, especially in terms of Production Performance. This is especially useful in terms of planning, as well as both material and warehouse management. Is your manufacturing system totally integrated? Total integration between Process Control, MES and ERP is essential in today's business. The manufacturing system consists in the joint efforts of a variety of functions. Good integration can make a difference for attaining top-level efficiency: on the contrary, poor integration can hinder your efforts to improve plant performance.

7 7 2.3 IT issues Is your system properly integrated and synchronized? Are there so many links between applications that communication is difficult? Are your IT maintenance costs too high? A myriad of links between your software packages greatly increases the complexity of the manufacturing system. In turn, costs for IT maintenance and program modification become staggering. This is mainly due to the lack of coordination and flexibility of the majority of manufacturing applications. The modeling approach can effectively simplify integration and actively coordinate the interaction and the flow of information between different applications on site. Is implementation too expensive? Do you frequently assess projects as falling in the "high-risk" category? Being able to employ reusable solutions creates the conditions for streamlining and speeding up project implementations. Total ownership costs can be cut dramatically, thanks to efficient software reusability. Does sharing your know-how represent an obstacle? Would you like to re-use your expertise and your software effortlessly? Efficient reusability of software is key to effective cost saving. Being able to "code" the expertise permits the rapid transfer of know-how between users, which is usually not feasible with standard applications. Without a modeling environment to help you define business procedures, focusing on the production process rather than specific IT issues, the understanding of complex manufacturing applications is rather difficult, making it virtually impossible to modify or reutilize code. Do you need a more streamlined environment for monitoring and troubleshooting? Typically, a production system is a complex integration of software applications and physical devices. Pinpointing problems and debugging are serious issues that require a great deal of effort and ultimately cost money. If you are able to model and run programs and business procedures from a single environment involving several systems, then extended monitoring and troubleshooting become more than just a possibility. Is it difficult for you to maintain your team s technological skills at top level? Are the costs to train your staff in line with state-of-the-art technology excessive? Applications are very often numerous and customized to satisfy specific needs. As a result, frequently, the person with the most know-how is used to develop and maintain these applications. Such competence is very difficult to maintain, as well as very expensive. By adopting SIMATIC IT, which covers all functionalities in an integrated and homogenous environment, complex manufacturing systems can be implemented with ease, making the tasks involved viable even for those users who possess normal skills.

8 8 3 How you can succeed 3.1 The SIMATIC IT model for Discrete Industry The challenges in today's manufacturing environments are becoming more and more exacting and manufacturers need from their supplier solutions that provide tangible benefits with quantifiable and quick return on investment. To increase competitiveness, manufacturers need to simultaneously reduce time-tomarket and cope with shorter product life cycles, increase visibility and comply with regulatory demands, optimize forecasting and scheduling, and reduce scrap, stock levels and downtimes; all while ensuring optimal quality and production efficiency across all global facilities. In an enterprise IT architecture, this would translate in enabling communication and integration between the key IT components that are contributing to bringing products successfully to the market. In order to rationalize and speed up processes, product design/ideation data need to be seamlessly transferred to the actual engineering environment, where the manufacturing process and test/inspection points are defined. The engineering process is the critical link between product ideation and manufacturing. It s where ideas become industrialized reality true speed comes then when also these data are seamlessly transferred to the manufacturing floor for actual execution. Real-time capabilities and supply chain efficiency come from interoperability with the financial/administration software, managing customer orders and transferring them to the manufacturing level. In parallel, also the production floor needs to be ideally equipped and organized, in order to be able to produce in an efficient way, avoiding unforeseen problems with equipment capacity, energy use, etc. Therefore, our digital factory / Plant lifecycle management part of the portfolio enables virtual testing and commissioning of plants and their equipment, up front delivering the needed configurations for the automation layer, which in turn communicates with the manufacturing execution level.

9 9 All these interactions, managed by the Siemens Industrial Software portfolio, enable integration of the product and production lifecycles resulting in faster time-to market. In order to increase the efficiency of the manufacturing plants in a way that is Fully integrated with the ERP Compatible with new products defined in the engineering environment Compliant with legal quality requirements Complete with the reporting and analysis tools required to support operations staff Siemens has organized its Discrete Portfolio for Manufacturing Execution into modular software packages that can be rolled out and maintained with a very low TCO. Modules for the Mechatronics Assembly Line environment address issues about Traceability Defect logging and repair Interlocking Modules for the Aerospace and Complex Manufacturing environment address issues about Order Management Production Routing Management Operation Execution Quality Management Electronic Work Instructions & Data Collection Points Interoperability with PLM 3.2 Business Benefits SIMATIC IT Production Suite fills the gap between Business Logistic Systems (typically ERPs) and Control Systems, providing the conditions for increasing overall supply-chain efficiency. The unique approach of SIMATIC IT allows manufacturing systems to have a native flexibility that gives users the possibility to easi- more cus- ly adapt and modify the business process to new requirements and business drivers. SIMATIC IT Production Suite allows manufacturers to model their own business to be much tomer-oriented and ready to satisfy any on-the-fly requirements from the market. SIMATIC IT Production Suite has also been designed to facilitate application roll-out to several plants, thus being extremely cost-effective in multi-site contexts.

10 10 The SIMATIC IT Discrete portfolio comes off-the-shelf with implemented industry specific manufacturing processes. The SIMATIC IT Discrete Solutions effectively help users to comply with existing regulations. 3.3 Production Benefits SIMATIC IT Production Suite offers a set of modules able to cover the MES core requirements in any manufacturing context. By modeling and defining production procedures, SIMATIC IT Production Suite effectively increases visibility on the entire production process. Tracking and tracing of materials and activity performed can be configured in order to match the actual process with the desired level of detail. Having a clear view of material usage makes it possible to reduce stock, analyze production costs in greater detail and manage scraps and reworks in an efficient manner. SIMATIC IT Production Suite can rebuild the complete material genealogy. SIMATIC IT coordinates and integrates a variety of systems, each with its own scope, thereby providing true added value to the production system as a whole. 3.4 IT Benefits The basic approach of SIMATIC IT makes it possible to model business rules in a graphical way so as to represent the interactions and the expected flow of information among different software components (including those that are not part of SIMATIC IT Production Suite). SIMATIC IT Libraries, classes and inheritance mechanisms create the conditions for an effortless rollout and reutilization of SIMATIC IT Production Suite applications. SIMATIC IT Production Suite permits users to focus on process issues, rather than IT issues. In SIMATIC IT Production Suite, technological aspects are transparent to the user, who, as a result, requires fewer skills than what is normally required to develop standard MES implementations. Costs for maintenance and application modification are pared to the bone.

11 11 4 SIMATIC IT Industry Libraries Discrete for Mechatronics Assembly Line The Mechatronics Assembly Line solution is an application that provides standard functionalities required in the mechanical and electronic assembly industries and it is used mainly on the production shop floor covering product data collection, operator activity assistance and traceability information retrieval. SIMATIC IT Mechatronics Assembly Line solution is used both for electronic and mechanical assembly and for material transformation with automatic and/or manual operations. Next picture is a synoptic of the functional capabilities. SIMATIC IT Mechatronics Assembly Line solution functions are grouped together into three software modules: Traceability Defect Logging Interlocking

12 Traceability This functionality is implemented in the ILD-MAL-RT solution and is responsible for storing every piece of information acquired from the shop-floor level and tracking work operations performed on materials in the form of Lot Operations in SIMATIC IT Material Manager. Tracking information is thus made available in terms of material lot history for interlocking checks and production reporting. Such functions are accomplished by means both of standard SIMATIC IT features and dedicated Custom Objects. Basic Production Order Management In order to model production orders, manage their status and assigned serial numbers, reassign produced items among orders. Process and component traceability, genealogy The system tracks all work operations and measures performed on serialized components, including process parameters and assembly steps. Used component batches are associated with the produced items too. Monitor work in progress (WIP) By work operation, product and order. Online Performance Monitor To display production performance and quality, by shift and product. Interfaces Information typically managed in electronics NPI tools, such as layouts and schematics, can be imported from Unicam Fx and Test Expert. 4.2 Defect Logging The Mechatronics Assembly Line solution provides a full set of functions to collect and manage defects. This includes the complete handling of defect objects, such as: Defect Groups Defect Causes Defect Types Defect Properties Defect Severities Defect Statuses. Electronics features include setting up a hierarchical defect catalog and displaying PCB layouts and Box graphical images to detect and repair defects. When a defect is discovered and evaluated, follow up actions can be triggered and a specific repair client is available for fixing the defect and recover. Creating or importing a defect catalog Associating defects from the catalog with produced items at run-time This feature includes graphical support for manual defect logging, specialized for PCBs and mechanical assemblies. Inspection instructions are available. Repairing defects The repair operator can view logged defects and close them adding notes. Repair instructions are available. Defect browsing This function allows the user to explore the defects database, through a configurable selection set, supporting the preventive actions and providing meaningful information for Root Cause Analysis.

13 Interlocking This functionality is implemented in the ILD-MAL-RT solution and it is the active part of ILD-MAL, which allows the system to check whether a material item is at the right place at the right time, whether it has been processed correctly up to now and which work operation can be carried out. If these checks fail, production can be stopped. This functionality is achieved through the exchange of synchronous messages between the interlocking client (issuing the interlocking requests) and the application server (processing the requests and taking the appropriate actions). Loop Cycle (checks how many times a process step has been executed) Process Routing (checks the sequence of process steps) Process Status (checks the result of previous process steps based on status) Time Between Steps (checks the time between two process steps) Serial Pattern (verifies the pattern of serial numbers) Material Parameter (retrieves items from the bill of materials) Material Location (checks the compatibility between workstation and operation) Material Compatibility(verifies the correctness of the component) List of Work Operations (checks the result of a list of previous process steps based on status) Order Status (verifies the production order status and retrieves its final material) Correct Order (checks if the workstation setup is compatible with the production order) The system is designed to allow the addition of project-specific checks. 4.4 Reporting With the adoption of Reporting Framework, an optional component of SIMATIC IT suite, it is possible to access to some standard reports that are specifically designed for this industry. Defect pareto Defect per Million Measure Result by Work Operation Process/Work Operation by material FPY (First Pass Yeld) Material Report FPY Material by date Serial Number Component Traceability Order Component Traceability Reporting can be then customized according to project needs. 4.5 Communication SIMATIC IT Mechatronics relies on the fact that every piece of equipment sends messages with appropriate sets of relevant data, concerning the operation performed: Produced Item ID Work Operation ID Terminal ID Order ID Other data (assembled/disassembled components, test results, defects, measurements, properties, etc.)

14 14 Communication is based on exchanging text messages between the system and external applications by means of several predefined interfaces: An asynchronous interface to the file system to exchange messages as text files Synchronous interfaces to exchange messages as text files, i.e. with a new file as an answer text strings, by means of predefined web services or public C# methods An OPC Client interface to exchange messages as character arrays with an OPC Server synchronously

15 15 5 Major features in version 2.3 SP1 What s New in SIMATIC IT for Discrete Industry Mechatronics Assembly Line v 2.3 SP1 Usability New functions New Reports SIMATIC IT for Discrete Industry Mechatronics Assembly Line v now supports also Microsoft Operating System Windows Server 2012 R2 (Standard and Enterprise, x64) Feature Description Area of Impact Extension to Reference Designators for Component Traceability Level 3 To give very detailed component traceability, also about component position on electronics boards, a reference designator location tracing is now available. New Function Adding and Enhancing Reports New: Measure Result by Work Operation Enhanced: Component traceability Report and Order Component Traceability Report New Reports Schedule production orders using an external APS system This version provides compatibility with external APS systems to allow scheduling of operations. It is based on two way communication logic New Function Ability to Deny Operating on Defects in Production Client It is possible to configure defects that will be assigned by automated testers and prevent them from being repaired, modified, etc.. by an operator. New Function Usability and Configurability Enhancements Several usability and configurability enhancements will provide higher user experience and more efficient operation: Enhance usability of Machine Setup management web pages Enhance user feedback of interlocking check Filter BoM items in the Assembly Client according to the work operation WO as a Filtering Criteria in Test plan Engineering Configurability of Component Extended Usability

16 16 Manufacturers Properties in PCB Client Serial Number Report Highlighting Interlocking checks where no check is performed