Holonic Manufacturing Execution System

Transcription

1 ic Manufacturing Execution System Fan-Tien Cheng Institute of Manufacturing Engineering National Cheng Kung University Tainan, Taiwan, R.O.C. July 14,

2 Outlines Introduction Basic Foundations Development of ic Manufacturing Execution Systems Development of WIP s Implementation and System Integration Summary and Conclusions 2

3 Outlines Introduction Basic Foundations Development of ic Manufacturing Execution Systems Development of WIP s Implementation and System Integration Summary and Conclusions 3

4 Introduction Background Motivation and Purposes 4

5 Introduction Manufacturing Objectives Cost Reduction Cycle-Time Reduction Yield Improvement Empowerment Agility WIP Visibility Asset Utilization On-Time Delivery Failure recovery Security certification 5

6 Background - MES Framework Introduction Application 1 Applications Other Component Scheduler Design Pattern B System Management Design Pattern A Equipment Management Design Pattern A Labor Management Design Pattern A Material Management Design Pattern A Components MES Framework Object Request Broker CORBA Infrastructure Object Services Common Facilities 6

7 Motivation and Purposes - Introduction Characteristics of ic Manufacturing Systems Intelligence Autonomy Cooperation Reconfigurability Extensibility 7

8 Introduction Motivation and Purposes - Deployment Diagram for ic Manufacturing Execution Systems Data Warehouse Shop-Floor WIP Scheduling Material Handling Equipment Equipment Robot AS/RS AGV 8

9 Outlines Introduction Basic Foundations Development of ic Manufacturing Execution Systems Development of Scheduling s Development of WIP s Implementation and System Integration Summary and Conclusions 9

10 Basic Foundations UML CORBA MES Framework Development Procedure for OO Systems 10

11 Basic Foundations rules for external behavior Subordination to whole Co - operation with peers Super - ordination to parts (sub - holons) co - operation Co - ordination with environment co - operation co - operation boundary internal structure & rules Material s Equipment s Scheduling Job _1 Job _2 11

12 Basic Foundations UML (Unified Modeling Language) Use Case Diagram Class Diagram State Diagram Sequence Diagram Collaboration Diagram 12

13 Basic Foundations CORBA (Common Object Request Broker Architecture) Application Interfaces Domain Interfaces Common Facilities Object Request Broker Object Services Object Implementation OMG Reference Model Architecture Client Dynamic Invocation Client IDL stubs ORB interface Static IDL Skeletons Dynamic Skeleton Invocation Basic Object Adapter Repository Im plem entation Interface Repository ORB core The Structure of a CORBA ORB 13

14 MES Framework Architecture Basic Foundations Application 1 Applications Other Component Scheduler Design Pattern B System Management Design Pattern A Equipment Management Design Pattern A Labor Management Design Pattern A Material Management Design Pattern A Components MES Framework Object Request Broker CORBA Infrastructure Object Services 14 Common Facilities

15 Development Procedure for OO Systems Basic Foundations Collect and study domain knowledge Collect requirements System Analysis Analyze requirements Define Use Cases initial sequence diagram for each scenario produce Identify each scenario in each Use Case refine OOA initial class diagrams produce Find classes Find classes' relationships and their operations/attributes Refine sequence diagrams iterative OOD Key mechanism final class, state, &interaction diagrams produce Design complete System implementation Implementation System integration and testing 15 Integration and Testing

16 Outlines Introduction Basic Foundations Development of ic Manufacturing Execution Systems Development of WIP s Implementation and System Integration Summary and Conclusions 16

17 Development of ic Manufacturing Execution Systems Development Procedure for HMES Collect Domain Requirements and Analyze Domain Knowledge Holarchy Design Construct Abstract Object Model Partition Application Domain into Components Identify Generic Functions Develop the Generic Define Holarchy Messages Holarchy Framework of HMES 17

18 Development of ic Manufacturing Execution Systems Development Procedure for HMES Collect Domain Requirements System Analysis Analyze Domain Knowledge Modify Construct Abstract Object Model Partition Application Domain into Components Identify Generic Functions among Functional s Develop Generic Holarchy Design Define Holarchy Messages Modify Define Holarchy Framework of HMES Design Functional s Based on Generic Functional s Design and Implementation Construct Applications Application Construction Integrate System and Test It 18 System Integration and Testing

19 System Analysis Manufacturing Objectives shown in pp. 5. Open Interfaces Modularization Distribution Configurability Interoperability Maintainability Security Certification Failure Recovery 19

20 Holarchy Design -- Construct Abstract Object Model Factory Area Data Warehouse Support all objects to access data 0...* 0...* 0...* 0...* Labor Material Equipment WIP Manages 0...* Labor Manages 0...* Material Manages Equipment Manages 0...* 0...* 0...* 0...* WIP 0...* 0...* 0...* 0...* 0...* 0...* Controls Dispatches jobs Shop-Floor Dispatches orders Scheduling 20

21 Holarchy Design -- Partition Application Domain into Components Factory Area Data Warehouse Support all objects to access data 0...* 0...* 0...* 0...* Labor Management Component Labor Manages 0...* Labor 0...* 0...* Material Material Management Component Manages 0...* Material 0...* 0...* Equipment Equipment Management Component Manages 0...* Equipment 0...* 0...* WIP WIP Management Component Manages 0...* WIP 0...* 0...* Controls Dispatches jobs Shop-Floor Management Component Shop-Floor Dispatches orders Scheduling Scheduling Component 21

22 Holarchy Design -- Identify Generic Functions among Functional s Intelligence Mechanism Exception Detection Exception Diagnosis Search Mechanism Collaboration Reconfigurability Security Mechanism Security Certification Data Encryption Data Decryption 22

23 Holarchy Design -- Develop the Generic Requirements of GH Use Case Diagram for GH Sequence Diagram for Diagnosing Exceptions Class Diagram of Generic Generic Internal Architecture 23

24 Holarchy Design -- Develop the Generic Requirements of GH It can construct the message backbone for cooperation and communication purposes. It provides the mechanism for security. It provides the ability of error diagnosis. It provides the ability of searching the desired services. It provides the ability of establishing a database service for information storage. 24

25 Holarchy Design -- Develop the Generic Use Case Diagram for GH Construct communication backbone Functional Search desired services Use security mechanism <<USE>> <<USE>> Use intelligence mechanism Connect to local database 25 Database

26 Holarchy Design -- Develop the Generic Sequence Diagram for Diagnosing Exceptions (OOA) : Functional : Kernel : Configuration : Database 1: Send exceptions 2: Diagnose exception 3: Get extension rules Return error level 4: Reasoning 26

27 Holarchy Design -- Develop the Generic Class Diagram of Generic (OOD) CORBAInterface InitializeORB() CreatObject() CloseObject() SetInterceptor() Kernel construct CORBA ORB SetInitialService() SetDBConnection() SetRegistration() SetEncrypt() SetDecrypt() SetExceptionTest() SetSearchData() use manage/ use use SecurityMechanism Validate() Encrypt() Decrypt() retrieve LocalDatabase Connection() RetrieveData() UpdateData() use KnowledgeBase 27 SearchEngine() Diagnose() AddRule() Match() RuleFilter() Configuration

28 Holarchy Design -- Develop the Generic Generic Internal Architecture Security Mechanism Local Database Knowledge Base Kernel CORBAInterface 28

29 Holarchy Design -- Define Holarchy Messages Fully-Automated Holarchy Messages Sequence Diagram Collaboration Diagram Semi-Automated Holarchy Messages Sequence Diagram Collaboration Diagram 29

30 Holarchy Design -- Define Holarchy Messages Fully-Automated Holarchy Messages - Sequence Diagram : External User Shop-Floor Scheduling AS/RS AGV Robot EM WIP Data Warehouse place an order save order inforamtion dispatch order get WIP status get item master, equipment status, and order status shceduling dispatch job dispatch job dispatch job dispatch job retrieve lot from AS/RS track out (retrieving from AS/RS) return track-out result update lot status setup paremeter [if wrong lot] store wrong lot and retrieve the correct one get BOM and recipe move lot to AGV transport lot to equipment Loop back if the order was not done. track in (in equipment) return track-in result update lot status 30 [if track in fail] move to next equipment

31 Holarchy Design -- Define Holarchy Messages Fully-Automated Holarchy Messages - Sequence Diagram(Cont d) : External User Shop-Floor Scheduling AS/RS AGV Robot EM WIP Data Warehouse [if track in fail] move to next equipment notify robot to pick up the lot move lot to equipment validate lot equipment start process update equipment status finish job move lot to AGV track out (in equipment) update lot status track out job done transport lot to next station move lot to AS/RS track in (storing in AS/RS) send storing information update lot status store lot in AS/RS report order done order done 31

32 Holarchy Design -- Define Holarchy Messages Fully-Automated Holarchy Messages - Collaboration Diagram move lot to AGV order done move lot to AS/RS External User place an order report order done Shop-Floor dispatch order Scheduling get WIP status WIP dispatch job track in track out AS/RS dispatch job return track-out result send storing information get item master, equipment status, and order status Equipment Management get item master, BOM get BOM nad recipe update equipment status finish job dispatch job dispatch job Robot AGV notify robot to pick up the lot return track-in result return track-out result track in track out save order information update lot status 32 Data Warehouse

33 Holarchy Design -- Define Holarchy Messages Semi-Automated Holarchy Messages - Sequence Diagram : External User Shop-Floor Scheduling Material Mover LM : Equipment Operator EM WIP Data Warehouse place an order save order information dispatch order get WIP status get item master, equipment status, and order status scheduling dispatch job if different product [if different product] assign setup job transport lot assign equipment setup job lot arrives setup equipment get BOM and recipe do track-in job scan barcode validate lot 33 track in

34 Holarchy Design -- Define Holarchy Messages Semi-Automated Holarchy Messages - Sequence Diagram (Cont d) : External User Shop-Floor Scheduling Material Mover LM : Equipment Operator EM WIP Data Warehouse validate lot track in start equipment update lot status equipment start process update equipment status equipment job done do track-out job scan barcode track out update lot status track-out job done Loop back if the order was not done. track-out job done transport lot to next station order done report order done 34

35 Holarchy Design -- Define Holarchy Messages Semi-Automated Holarchy Messages - Collaboration Diagram order done dispatch job lot arrives External User track out job done Material Mover report order done place an order track out job done assign setup job dispatch order equipment job done Shop-Floor Scheduling get WIP status WIP track in track out get item master, BOM get item master, equipment status, and order status Equipment Management get BOM nad recipe update equipment status setup equipment scan barcode start equipment Labor Management assign equipment setup job do track-in job do track-out job save order information update lot status Data Warehouse Equipment Operator 35

36 Holarchy Design -- Holarchy Framework of HMES Application 1 Applications Exchange Scheduling Shop-Floor Equipment WIP Material Functional s Holarchy G H G H G H G H G H G H Object Request Broker CORBA Infrastructure Object Services Common Facilities 36

37 Outlines Introduction Basic Foundations Development of ic Manufacturing Execution Systems Development of WIP s Implementation and System Integration Summary and Conclusions 37

38 Development of WIP s Requirements for WIP s Object-Oriented Analysis Object-Oriented Design 38

39 Development of WIP s Requirements for WIP Real-Time Update WIP Track by Process of Lots Provide Information for Other s Provide Information for Users Ability of Accessing DBMS Open Interfaces Error Recovery Security Certification 39

40 Holarchy Messages of WIP Development of WIP s Scheduling get WIP status get BOM, item master update WIP status track in, track out WIP track in, track out Data Warehouse return track-in result return track-out result return track-in result, return track-out result AS/RS 40 AGV

41 Development of WIP s Use Case Diagram for WIP External User Common Database Generic Evaluator Track out Track in Provide lot information Handle Exceptions User 41 Login System

42 Creating New WIP Object (OOA) Development of WIP s : External User : WIP Manager : WIP : Common Database create new WIPs generate new WIPs get BOM get item master get order status 42

43 Regular Track in (OOA) Development of WIP s WIP Manager WIP : External User track in Functional asks to track in. get specific WIP track in get BOM on Eq [if wrong Eq]send wrong Eq message check BOM and process sequence [if wrong BOM]send wrong BOM message [if OK]send starting processing message return track-in result update WIP status 43

44 User Login System (OOA) Development of WIP s : User User Interface WIP Manager enter user information send user information check user's authority [if granted] enable track-in functions [if granted] enable track-out functions [if granted] enable query functions 44

45 Development of WIP s OOA-Stage Class Diagram Generic Kernel Configuration User Interface WIP Manager use Recovery Manager manage 0...* WIP 45

46 Creating New WIP Object (OOD) Development of WIP s : External User : WIPManager : WIP : BOM : ItemMaster : Common Database CreateNewWIPs(lotID,quality,count) WIP() NewVariables() get BOM Constructor of WIP Class NewVariables() get Item Master get order status 46

47 Regular Track in (OOD) Development of WIP s : External User : WIPManager : WIP DoTrackin(Barcode, Station) Trackin(Barcode, Station) Returns TRUE if track-in is ok. Searches WIP by parameters See Sequence Diagram of "Track in" 47

48 Track in Operation (OOD) Development of WIP s : WIPManager : UserInterface : WIP : Common Database get BOM on Eq CheckBOM&PS () ShowCheckResult () Checks BOM and process sequence. [if this track-in is the last station]deleterepository(lotid) These operations happen when the track-in is on last station. save WIP status [if this track-in is the last station]deleteme() 48

49 User Login System (OOD) Development of WIP s : User : UserInterface : WIPManager : Security Mechanism enter user information Login(userID, password) SetRegistration(userID,password) Validate(userID,password ) [if granted] EnableTrackin() [if granted] EnableTrackout() [if granted] EnableQuery() 49

50 Development of WIP s OOD-Stage Class Diagram CORBAInterface Configuration SecurityMechanism retrieve LocalDatabase InitialORB() CreatObject() CloseObject() Validate() Encrypt() Decrypt() Connection() RetrieveData() UpdateData() construct CORBA ORB use Kernel SetInitialService() SetDBConnection() SetRegistration() SetEncrypt() SetDecrypt() SetErrorTest() SetSearchData() manage/ use use use KnowledgeBase SearchEngine() Diagnose() AddRule() Match() RuleFilter() Generic WIPManager UserInterface + Login() + Trackin() + Trackout() + Query() - EnableTrackout() - EnableQuery() - EnableTrackin() - ShowCheckResult() - ShowTrackoutResult() - ShowQueryResult() + CreateNewWIP() + DoTrackin() + DoTrackout() + Query() + SendException() - KillRepository() - ValidateID() - Recover() - SaveLog() manage use RecoveryManager - ReConnectLDB() - TryConnection() - AlarmAGV() - AlarmASRS() - AlarmRobot() BOM - NewVariables() use 0...* WIP LotID : String = initval Barcode : String = initval StorageX : Integer = initval StorageY : Integer = initval Quality : Integer = initval Type : String = initval Station : String = initval BOM : Object = initval ItemMaster : Object = initval OrderID : type = initval use ItemMaster - NewVariables() 50 - Trackin() - Trackout() - DestroyMe() - GetStructure() - CheckBOM&PS()

51 Development of WIP s State Diagram of WIP Object Life Cycle start Create WIP do: WIP Create BOM do: BOM:NewVariables Create Item Master do: ItemMaster:NewVariables Getting order status All WIP initial information is collected query request track-out request Do track-out do: Trackout Provide WIP status do: GetStructure Wait for request [not last process] track-in request Do track-in do: Trackin Store WIP status to database Store WIP status to Database [last process] Delete the WIP repository do:wip:deleterepository Delete WIP do:deleteme 51 end

52 Development of WIP s State Diagram of WIP End [if not granted] start User Login the System do: Login [if granted] Initiate CORBA Service do: SetInitialService Receives creating command WIP Object Life Cycle [If last process finished] End [An Exception occurred] Diagnose do: SetExceptionTest Do Recovery Operation do: Recovery [Recovery failed] Send an Alarm [Recovery successful] Back to the last operation where the exception is occurred End 52

53 Outlines Introduction Basic Foundations Development of ic Manufacturing Execution Systems Development of Scheduling s Development of WIP s Implementation and System Integration Summary and Conclusions 53

54 Implementation and System Integration System Deployment Architecture Functional s Implementation Procedure Application Construction with System Integration 54

55 Implementation and System Integration System Deployment Architecture Data Warehouse Shop-Floor WIP Scheduling Material Handling Equipment Equipment Robot AS/RS AGV 55

56 Implementation and System Integration Functional s Implementation Procedure 1. Generic Development 1 Generic Development 2. HMES Framework 2 Define Functional Framework IDL idl2java 3B-1 Client Stub 3A-1 Server Skeleton 3B-2 Implement Functional Client 3A-2 Implement Functional Server javac javac 3B-3 Locate Servers of other Functional s 3A-3 Register Functional Server javac 3. Functional Development 4 Functional Ready 56

57 Implementation and System Integration Application Example for Getting WIP Status Scheduling WIP Common Database SH:Scheduling Manager SH:Information Manager WH:WIPManager WH:WIP : Common Database GetWIPStatus(lotID) Returns a structure of WIPStatus including "Barcode", "lotid", "Station", "Quantity", and "Type" Query(Barcode,lotID,Station) [if WIP exists]getstructure() [if WIP doesn't exist]get WIP's record 57

58 Outlines Introduction Basic Foundations Development of ic Manufacturing Execution Systems Development of Scheduling s Development of WIP s Implementation Summary and Conclusions 58

59 Summary and Conclusions Comparisons between MES and HMES Summary and Conclusion 59

60 Summary and Conclusions Comparisons between MES and HMES Legacy MES MES HMES Framework Framework Architecture Centralization Distributed OO Holarchy Open Interfaces No Yes Yes Modularization Low High High Interoperability Low High High Configurability Low High High Cost High Low Low Maintainability Difficult Easy Easy Security Certification No No Yes Failure Recovery No No Yes *Legacy MES: Promis, WorkStream, etc., Framework MES: SiView, FACTORYWorks, etc., 60

61 Summary and Conclusions Present a new concept for developing next generation Manufacturing Execution Systems. Provide a systematic procedure to develop holonic manufacturing systems. Demonstrate the feasibility and capability of HMES by designing and implementing a WIP. 61

62 Thanks. 62