The Wonderware Enterprise Integration Application. By Tim Sowell, Vice President of Product Strategy for Wonderware

Transcription

1 The Wonderware Enterprise Integration Application By Tim Sowell, Vice President of Product Strategy for Wonderware

2 Table of Contents 1. Highlights Capabilities Industry Standards Library of Pre-Built Integration Templates Components Benefits The Ability to Traverse a Business Varying Security Models Multiple-Enterprise and Supply-Chain Application Integration Scalability Built-In Administration Tools Integrated Real-Time Event Engine Powerful Orchestration Environment Transform and Map Schemas for Subsequent Re-Use The ArchestrA Architecture s Real-Time Application Integration Platform for Services Synchronized Information Flow Coupled with Independent, Continuous Plant Operations Managing Master Data for Manufacturing Operations The Ability to Locally Dispatch Production Work Orders Application Assembly, Not Programming Centralized Topology Mapping between Business and Manufacturing Systems Ensuring Successful Implementation through Qualified System Integrators Enterprise Partnerships Summary...19 The Wonderware Enterprise Integration Application Page 2

3 1. Highlights In today s competitive and dynamic manufacturing environment, there is a critical need to complete the manufacturing supply chain by linking manufacturing systems and business applications. The Wonderware Enterprise Integration Application facilitates this fundamental enterprise integration, empowering Wonderware customers to achieve sustainable profitability through full synchronization between business and manufacturing systems. Wonderware's Enterprise Integration Application enables: Configurable transactional integration with business applications, including: o Integration of manufacturing systems with enterprise business systems (e.g., SAP, Oracle, J.D. Edwards); o Operational integration between multiple manufacturing sites and solutions (i.e., a product completed at one plant can then be utilized at another plant); o Transactional integration between manufacturing and other supply-chain applications in a manufacturing environment (e.g., advanced-planning, LIMS, PLM and quality-management systems); and o Integration with existing messaging and middleware investments (e.g., WebSphere, TIBCO, MQ Series), aligned with existing infrastructure and IT strategies. Master data management for manufacturing operations o There is a repository for all information related to manufacturing operations, facilitating the execution and coordination of manufacturing operations. Localized dispatching of production work orders o Release individual production work orders to actual manufacturing resources on the plant floor, for faster execution and increased accuracy in execution. Adoption of industry standards o Total cost of ownership (TCO) can be reduced by adopting industry standards for the integration of enterprise and control systems and for manufacturing interoperability. The Wonderware Enterprise Integration Application encapsulates and re-uses engineering and best practices in accordance with these standards. The Wonderware Enterprise Integration Application Page 3

4 Fig. 1: High-Level Positioning of Wonderware s Enterprise Integration Application Wonderware s Enterprise Integration Application can operate automatically. It can transparently send and receive messages. It can transform and modify message content while controlling the sequence of operations required to maintain connections between two or more applications. The Wonderware Enterprise Integration Application leverages ArchestrA technology to provide a highly flexible real-time event system. It also offers powerful orchestration and workflow management functions. It serves as a transactional-messaging integration layer to the ArchestrA architecture. As a result, Wonderware customers benefit from: Complete architectural freedom; Out-of-the-box integration to hundreds of applications in both the manufacturing automation space and business applications; Powerful graphical configuration that enables assembly, rather than programming, of message transformation and event detection; Configuration of workflow transformations and real-time event mappings, so they can be easily established and maintained; and The Wonderware Enterprise Integration Application Page 4

5 A very flexible, robust architecture, which enables existing business and manufacturing systems to work in a complementary fashion that is loosely coupled yet extremely reliable. In essence, the Wonderware Enterprise Integration Application addresses the current need for transactional business integration in manufacturing automation systems. 2. Capabilities Wonderware recognizes the importance of providing an integration solution that avoids the complexity of creating and maintaining proprietary interfaces, while still providing the following capabilities: Powerful orchestration of multiple-application workflows; Transformation mapping in non-programmatic environments; Built-in event handling and integration of events within the manufacturing system; Scalability from a small pilot to multiple sites; Security between non-trusted environments; Robust message delivery through high-availability architectural options; Ability to build standards and re-usable rules, transformations and workflows that can be rolled out across multiple sites in the organization; Support for open information standards such as ISA-95 and the message structures defined in B2MML (Business-to-Manufacturing Markup Language) messages; Extended application messages and message structures that can be customized to fit specific applications; Seamless integration with Wonderware application components, as well as non- Wonderware automation packages and other databases; and Support for integration standards such as SQL, ODBC, XML and OLE. 3. Industry Standards An integrated manufacturing ecosystem is essential in today s market. Business and manufacturing systems must have loosely coupled solutions that interact in a non-intrusive manner. Message delivery must be robust, transparent and automated. This design philosophy enables each system to perform its duty at the required rate, while interacting with other systems in a timely manner. Following Wonderware s tradition for building solutions that employ robust, marketleading technologies and industry standards, the Wonderware Enterprise Integration Application leverages: The Wonderware Enterprise Integration Application Page 5

6 ISA-95 standards for manufacturing-to-enterprise integration. As a voting member of the ISA-95 committee, Wonderware actively provides direction for these standards; B2MML standards; MIMOSA (Machinery Information Management Open Systems Alliance) standards for collaborative asset lifecycle management; OAGIS (Open Applications Group Integration Specification) business-language standards for enterprise application interoperability; ArchestrA technology, which provides an open and flexible event system; The latest Microsoft technologies; The OPC protocol for real-time connectivity to plants; and SQL/OLE database support and database integration. By combining these standards and technologies with proven libraries of pre-built integration applications, manufacturers systems can get up and running faster and with lower risk. 4. Library of Pre-Built Integration Templates Wonderware offers a library of pre-built integration templates that leverage ArchestrA technology and enable customization for each application. These templates are appropriate for a wide variety of integration scenarios. The following are some examples of what can be done with these powerful templates. Download production schedules from ERP systems The Enterprise Integration Application uses B2MML messaging to create and schedule work in the manufacturing environment, enabling an ISA-95 schedule to automatically create batches and lots that are ready to be executed. Upload performance-optimizing production parameters throughout the work order cycle An Enterprise Integration Application template can configure ISA-95 process segments and events relative to the existing manufacturing model. The Enterprise Integration Application can also upload production parameters into ISA- 95 (B2MML) production performance documents. Integrate transactions between Wonderware s InBatch, InTrack and Industrial Application Server software -- Using Enterprise Integration Application templates, you can use an InTrack system as a manufacturing model, take advantage of InBatch scheduling and batch execution, upload data on batch results and consumables back into the InTrack software during completion, and include this information in the production history. Another template utilizes InTrack features to integrate manufacturing facilities where products can be The Wonderware Enterprise Integration Application Page 6

7 shipped from one InTrack system and automatically received by another, based on production events. Leverage automatic integration of KPI data -- Enterprise Integration Application templates can also assist in the automatic transference of KPI data from a condition-based monitoring system on the plant floor to the computer maintenance system. These pre-built integration templates are under constant development, so this list will continue to grow. 5. Components While possible topologies will be discussed later, it is important to understand the following key modules of the Wonderware Enterprise Integration Application: Business orchestration module This module provides workflow and transformation capabilities that can interface with messaging systems and APIs (application programming interfaces). It leverages Microsoft BizTalk Server technology and a range of adaptors available on the market. There is an interface between the business orchestration module and the manufacturing module, which can pass across firewalls. Manufacturing module This is the module that resides within the manufacturing automation system, either apart from the system (when Wonderware s Industrial Application Server is already installed) or on top of the existing automation system. The manufacturing module acts as a real-time event engine and integrates with existing plant system(s) through the SuiteLink protocol, DDE, OPC or SQL as a result of ArchestrA technology. This module will be independent of the business orchestration module. It includes a production database in Microsoft SQL Server that uses an ISA-95 database schema for all the different sections of the standard, such as the planned and actual data. This module also enables the downloading of schedules that can be stored in the ERP until required for use in the manufacturing system. The manufacturing module includes a repository for all information related to manufacturing operations. It can store schedules, orders and product-specification data from ERP and PLM systems, as well as equipment-specific setup specifications and other information from sources like OEM machine builders. Finally, the manufacturing module enables production work orders to be dispatched locally The Wonderware Enterprise Integration Application Page 7

8 for the release of production work orders to actual manufacturing resources on the plant floor, such as packaging machines, mixing units or work centers. Application adaptors (optional) Wonderware has established a relationship with iway Software to provide adaptors for Microsoft BizTalk Server as part of the Enterprise Integration Application. (Please refer to the section called Partnership with iway.) Production dispatch client (optional) The Enterprise Integration Application s production dispatch client is the local client to the manufacturing module. It enables Wonderware customers to: Enter a schedule manually if the ERP system is down; Display proposed orders; Perform dispatching activities locally by correlating orders as well as product and equipment specifications, and assigning individual production work orders to specific production lines or work centers for execution; Assign captured production events to an ERP production order after the events have taken place; and Locally release production orders to manufacturing. 6. Benefits The significant benefits of Wonderware s Enterprise Integration Application are: 6.1. The Ability to Traverse a Business Varying Security Models Critical to today s integration solutions is the ability to interconnect applications that exist in different (often non-trusted) security domains without compromising the security of either domain or the applications. A secure, well planned business security model will have multiple firewalls that isolate the plant-floor applications from the rest of the enterprise. Yet to run an effective manufacturing ecosystem, these applications must pass messages. The Wonderware Enterprise Integration Application was designed to enable this integration in a secure environment Multiple-Enterprise and Supply-Chain Application Integration The Wonderware Enterprise Integration Application provides adaptors that connect to hundreds of enterprise applications, such as: ERP systems from SAP, Oracle Manufacturing, J.D. Edwards, Baan, i2 Technologies and Microsoft Dynamics (formerly MBS) - Axapta and Navision; as well as The Wonderware Enterprise Integration Application Page 8

9 Message interfaces from MSMQ, IBM MQ Series, Web Services, XML, OLE DB and SOAP Scalability To address an enterprise s future integration needs, the most logical approach is to start with a pilot and then scale up. The Wonderware Enterprise Integration Application provides the ability to scale the number of: Real-time plant connections; Workflows and transformations; and Application connections being integrated. With its flexible architecture (see the Centralized Topology section for details), the Wonderware Enterprise Integration Application provides the ability to evolve architectures to meet physical distribution requirements and fit existing IT structures. Examples include: A pilot with one plant connected to one business system; Multiple plants physically distributed and connected to one business system; and Single- or multiple-plant systems connected to multiple-business systems Built-In Administration Tools Central to both ArchestrA and Microsoft BizTalk Server technologies is the fundamental ability to administer and add instruments to the application, so that users can proactively address issues. By incorporating the Industrial Application Server s powerful real-time event system, users can be notified of errors as part of the plant alarming system, and notification can be both logged and sent via or telephone to select personnel. Through Wonderware s SuiteVoyager portal software, users can integrate powerful reporting and dashboard capabilities to bring the information to their fingertips Integrated Real-Time Event Engine The Enterprise Integration Application s event engine enables users to configure plant events and integrate them with installed plant automation systems, connecting through hundreds of interfaces and the open connectivity provided by OPC technology. Due to the distributed nature of the ArchestrA architecture, plant personnel can detect events by applying multiple distributed event engines. Even though these engines can be physically distributed, they are managed as one, and integrate seamlessly with one or more orchestration engines, which can be located in another domain and location. This provides unparalleled flexibility and highavailability options. The Wonderware Enterprise Integration Application Page 9

10 6.6. Powerful Orchestration Environment As illustrated in Fig. 2, the Enterprise Integration Application s orchestration environment enables the configuration of flow between applications. A user can create an unattended execution schedule that can be based either on time-related events or plant events defined in the real-time event engine, which is constantly receiving, transforming and forwarding messages. Fig. 2: Graphical Workflow Configuration 6.7. Transform and Map Schemas for Subsequent Re-Use The key to passing messages between applications is the ability to transform and map the different schemas. Through Microsoft BizTalk Server s powerful data mapper (see Fig. 3), users can build this mapping visually and save it as a reusable transformation from one workflow and project to another. The Wonderware Enterprise Integration Application Page 10

11 Fig. 3: Messaging Mapping 6.8. The ArchestrA Architecture s Real-Time Application Integration Platform for Services Because it s built on the ArchestrA architecture, the Enterprise Integration Application offers extensive services, especially those associated with alarming, events, customization and scripting. It also facilitates the creation of standards for real-time manufacturing and tight system-wide integration Synchronized Information Flow Coupled with Independent, Continuous Plant Operations Using the Production Dispatch Client (PDC), the Wonderware Enterprise Integration Application maintains close synchronization of information between plant and business systems, without interrupting operations -- even if the connection to a central ERP system is not available, and during planned downtime of the ERP system. The Wonderware Enterprise Integration Application Page 11

12 The production schedule and individual production orders can be created, modified and maintained manually, and locally released to manufacturing. The captured information is then assigned to an ERP production order, keeping the information in the appropriate context within the business system. Fig. 4: The Wonderware Enterprise Integration Application's Production Dispatch Client Management of Master Data for Manufacturing Operations Execution of manufacturing operations can be improved by synchronizing all the master data for manufacturing operations. The Wonderware Enterprise Integration Application can correlate production orders, product-specification data, quality specifications, sampling plans and equipment-specific setup specifications. It can also store schedules, orders and product-specification data from ERP and PLM systems. It can also contain equipment-specific setup specifications and other information from sources like OEM machine builders The Ability to Locally Dispatch Production Work Orders The Enterprise Integration Application can locally perform dispatching activities on individual production work orders using manufacturing resources that enable manufacturers to properly respond to deviations in the production schedule. This capability can be used to enhance equipment setups or to retain information from a golden batch. Business and manufacturing systems work best when leveraging loosely coupled solutions that interact in a non-intrusive manner. The Wonderware Enterprise Integration Application Page 12

13 The Enterprise Integration Application also enables manufacturing processes to run independently of business system availability. As a result, in a 24/7 manufacturing environment, plant staff can synchronize actual production records with production schedules Application Assembly, Not Programming Because it uses pre-built and tested adaptors to integrate applications and a component-based application model, Wonderware s Enterprise Integration Application is designed to enable configuration and assembly of solutions that avoid programming. 7. High-Availability Topology Complete architectural freedom is a key strength offered by the Wonderware Enterprise Integration Application. For situations in which the Enterprise Integration Application is being used to integrate business applications, we recommend the topology illustrated in Fig. 5. This topology is commonly found in companies that have a central business system and multiple physically distributed manufacturing sites. Fig. 5: Central ERP Wrapped in a Messaging System When implementing business systems, many organizations wrap them in middleware to enable the processing of incoming or outgoing messages to multiple sites and business applications. Many companies use products like Mercator, IBM WebSphere, TIBCO and Microsoft BizTalk Server to achieve this, and a corporate messaging system (e.g., MQSeries, The Wonderware Enterprise Integration Application Page 13

14 MSMQ, Web Services) to manage the delivery of these messages between different sites and applications. As an example, SAP s drive for implementing versions of its ERP central component (ECC) SAP 4.7 and SAP NetWeaver technology, this type of application architecture will become even more common, as NetWeaver provides a powerful transformation and business-flow environment for transforming incoming and outgoing messages to the appropriate calls within the R3 system. Especially in the manufacturing environment, where companies are striving for standard messages between different sites, many companies base their messages on ISA-95 (B2MML) standards. Having determined a common message structure at the business end, the proposed architecture places the Enterprise Integration Application at each site so that it can collect incoming messages and transform them into the required calls needed in that particular site. Usually, each manufacturing site will require its own transformation of standard messages. Here s a simplified example of the functional flow for this architecture: 1. The ERP system sends a schedule, which is transformed by the ERP middleware (let s say SAP NetWeaver XI) to the ISA-95 (B2MML) production-schedule message, and places it on the message bus. 2. The messaging system delivers the message to the correct manufacturing site. 3. The Enterprise Integration Application s business orchestration module collects the message at the manufacturing site and transforms it through workflows into the ISA-95 production database. This enables a production schedule to be stored locally. In case the SAP connection is lost, manufacturing will continue. This architecture facilitates the customization of workflows and mappings, as well as a manual entry system that enables schedules to be entered via a local terminal. 4. The Enterprise Integration Application s manufacturing module pulls the scheduled orders and makes the required calls to the batching/manufacturing execution system (MES) to start executing the orders. It also monitors all production events, collects the required data and transforms it to the ISA-95 production database, which is ready for uploading to the business system. 5. In the event of a particular process-update event or business-system request, the business orchestration module queries the ISA-95 production database, builds the required ISA-95 production-performance message and places it on the message bus. 6. The message system sends the message to the business system. 7. The business system s middleware collects the message and transforms it to the required calls in the business system. This example illustrates how the Wonderware Enterprise Integration Application The Wonderware Enterprise Integration Application Page 14

15 complements the business system s middleware to provide a loose coupling and robust architecture where a standard business interface can be established. This technique preserves common messaging structures while maintaining the uniqueness of each manufacturing site and the existing MES/batch systems that run those sites. Based on Wonderware s experience, this architecture is a good scalable, robust topology that suits most multi-site organizations. This approach is found in companies that have only one manufacturing site or where the business system is local to each site -- effectively, these companies run each site as its own business. This topology is also appropriate for companies with business systems that cannot be wrapped in standard middleware. While each company must be analyzed on a case-by-case basis, companies with multiple physically distributed manufacturing sites that plan to switch to a central business system should seriously consider the standard-messaging approach and architecture proposed in the first topology. 8. Mapping between Business and Manufacturing Systems The focus of the business system is different from that of the manufacturing or MES system and they should be in order to optimize the performance of their required tasks within the organization. Due to their different areas of specialization, different terminologies and groupings are applied, requiring resolution for optimal integration and interoperability. The ISA-95 standard (parts 1 and 2) provide a basis for these messages, but they do not provide all the structure. The World Batch Forum developed the B2MML message structure. Having implemented a number of ISA-95 integrations, Wonderware has found that these two standards (ISA-95 and B2MML) provide a solid basis for standard messaging -- providing approximately 80% of the structure. However, as would be expected, there should be room for customization according to the different sites. Leading end-users have often discussed applying these standards, particularly when mapping ISA-95 process segments to a structure in the SAP recipe and MES plant model (e.g., S-88 and ISA-95 part 3). The Wonderware Enterprise Integration Application Page 15

16 Fig. 6: Mapping Example Fig. 6 is a good example of a mapping topology in which numerous sites are mapped. (Note: this will vary by site and organization.) However, end-users with a common business system will strive to pass common messages between the business and manufacturing systems. Therefore, a standard set of mapping rules across the entire organization will be required. Wonderware has found from its business use cases that, typically, defining these mapping rules is the most challenging part of any implementation, especially the first project. In order to help with this problem, Wonderware offers consulting expertise to end-users as well as system integrators (SIs). 9. Ensuring Successful Implementations through Qualified System Integrators In order to ensure the highest-quality implementations, Wonderware has initiated a special system integrator qualification program specifically for the Wonderware Enterprise Integration Application. This program is designed to assist companies that are considering a Wonderware Enterprise Integration Application in the selection of the best integrator for the project. The Wonderware Enterprise Integration Application Page 16

17 Wonderware can recommend existing qualified Wonderware system integrators or provide application experts to work with a customer s preferred system integrator on the initial project in order to transfer knowledge and qualify the customer s system integrator. Due to the complex nature of system integration, integrators who implement successful business system-to-manufacturing systems must possess knowledge of both business and manufacturing systems. To verify this level of knowledge, Wonderware provides a qualification program for system integrators who would like to implement Wonderware Enterprise Integration Applications. The objectives of this program are to: Establish a global set of qualified system integrators to support implementations of the Wonderware Enterprise Integration Application, and Work with end-users to determine the best-qualified SIs in their local areas, and then work with the SIs to achieve qualification. Qualification can be achieved through training and collaboration with Wonderware enterprise integration specialists during the initial implementation. This program complements the overall Wonderware System Integrator Program. (Learn more about this program at In order to deploy the Wonderware Enterprise Integration Application, system integrators should be ArchestrA Certified SIs, or at least have the required skills and expertise to achieve this level of certification. Qualified SIs have been trained on how to successfully implement a Wonderware Enterprise Integration Application. They understand how to capture the right kind of information from the customer and determine the most appropriate implementation approach. They also possess knowledge pertaining to business rules and workflows, enabling them to link the business system to the manufacturing system. (The best approach can vary widely from organization to organization.) Who to Contact for Enterprise Integration Application Implementations Companies seeking an appropriate integrator for a Wonderware Enterprise Integration Application are encouraged to work with their local Wonderware contacts to jointly determine the ideal system Integration strategy for that specific Wonderware Enterprise Integration Application. (Find your local Wonderware Distributor at The Wonderware Enterprise Integration Application Page 17

18 10. Enterprise Partnerships SAP Wonderware is a Platinum Partner in SAP s Adaptive Manufacturing Program. Wonderware has worked closely with SAP on leveraging its ISA-95 standard to achieve optimal manufacturing-to-enterprise integration. In fact, the Wonderware Enterprise Integration Application achieved certification as part of the SAP's "Interoperability Certification" program, which recognizes applications that integrate industry standards such as ISA-95. In addition, Wonderware attained Powered by SAP NetWeaver certification for two new plant-to-business integration solutions. The first is Wonderware's Business Package for Process Performance Analysis 60.1, which is integrated with the SAP NetWeaver Portal. The second is the combination of the Wonderware Enterprise Integrator (version 2.0) with SAP s NetWeaver Exchange Infrastructure Content Package (based on SAP NetWeaver XI) for Order Processing 30.1 and ECC 5.0. This is only the initial step in Wonderware s drive to enhance business system alignment with manufacturing operations, working with SAP on their adaptive manufacturing initiative. iway Software Wonderware has partnered with iway Software for delivering compelling connectivity to virtually any business system, avoiding custom-built integration solutions that are difficult and costly to implement and maintain. iway's proven products, partners, and professional services are key to quickly and efficiently transforming business processes by integrating existing data, applications and environments with new systems and applications, including: Popular ERP, CRM and SCM application packages; Messaging technologies such as MQSeries; Application technologies like Java/J2EE/JCA and XML; and Internet technologies such as Web Services and.net. The Wonderware Enterprise Integration Application Page 18

19 The hallmark of iway Software is its simplicity, based on the assembly and configuration of off-the-shelf components. These components include more than 280 pre-built connections to virtually any back-office system, including legacy systems and packaged applications. The simplicity of iway Software enables companies to achieve rapid integration without lengthy custom coding or expensive system overhauls, and to implement mission-critical applications without costly delays. 11. Summary Wonderware s Enterprise Integration Application integrates manufacturing systems with enterprise business systems in a robust, reliable and scalable manner. Its uniquely flexible underlying architecture simplifies implementation and enables the re-use of engineering. Using the Wonderware Enterprise Integration Application, customers can avoid point-topoint systems and focus on their domain expertise. The powerful enterprise integration achieved by the Wonderware Enterprise Integration Application is achieved through application assembly rather than programming. It leverages proven integration adaptors and offers the flexibility required by today s most successful manufacturing businesses. Using the Wonderware Enterprise Integration Application, customers can reap the rewards of enterprise integration solutions that complement their existing systems, including traditional MES functionality, and grow with their business. In addition, Wonderware enterprise solutions can be painlessly combined with powerful Wonderware production and performance management solutions. In essence, the Wonderware Enterprise Integration Application enables manufacturers to improve operational performance by integrating diverse sets of manufacturing systems and business applications to achieve greater levels of business productivity. The Wonderware Enterprise Integration Application Page 19

20 Contact Wonderware or your local Wonderware Distributor for more information on industrial automation and information solutions. Wonderware Rancho Parkway South, Lake Forest, CA Tel: (949) Fax: (949) , 2006 by Invensys Systems, Inc. All rights reserved. No part of this document may be reproduced, stored in or introduced into a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise), or for any purpose, without the express written permission of Invensys Systems, Inc. Invensys, Wonderware, ArchestrA, InTrack, InBatch, IndustrialSQL Server, SuiteVoyager, SuiteLink, FactorySuite and FactorySuite A2 are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners. Part No ; 5/06 The Wonderware Enterprise Integration Application Page 20