Strategies for Integrating MES with other Enterprise Systems, Equipment and Controllers S. Willcott Solution Architect, Operations Informatics 2013 Illumina, Inc. All rights reserved. Illumina, IlluminaDx, BaseSpace, BeadArray, BeadXpress, cbot, CSPro, DASL, DesignStudio, Eco, GAIIx, Genetic Energy, Genome Analyzer, GenomeStudio, GoldenGate, HiScan, HiSeq, Infinium, iselect, MiSeq, Nextera, NuPCR, SeqMonitor, Solexa, TruSeq, TruSight, VeraCode, the pumpkin orange color, and the Genetic Energy streaming bases design are trademarks or registered trademarks of Illumina, Inc. All other brands and names contained herein are the property of their respective owners.
Agenda Domain separation and adoption of standards ISA95 Accidental architecture Integration patterns and pitfalls Loose coupling VETO Example Shop floor Level 3-2 Example Plan for the future Summary 2
Managing the supply chain 3
Consider Domain Separation 4
Consider what is value add Examine business processes From Strategy to Execution Examine product types MTS, MTO, ETO, ATO Identify domains of information Product, Quality, Inventory, Machines Identify standards for guidance ISA 95, MESA, APICS Review integration options 80/20 rule and phased approach Consider Service Oriented Architecture and design patterns Avoid tightly coupled systems, look for reuse 5
Business Processes 2-10 years Strategic Plan Production Plan Mater Production Schedule Planning Phase Material Requirements Plan 1-30 days Production Activity Control Execution 6
Product Type 7
Domains of information Plant production scheduling, operational management Business planning and logics Product Definition Production capability Production Schedule Production performance How to make it What resources are available When production will be executed What actually happened Manufacturing operations and control Production operations, maintenance operations, quality operations 8
Manufacturing Operations Management Production schedule Maintenance Request Quality Test Request Inventory Request Production performance Maintenance Response Quality Test Response Inventory Response Manufacturing Operations Production Operations Management Maintenance Operations Management Quality Operations Management Inventory Operations Management Product Definition Maintenance Definition Quality Test Definition Inventory Definition Production Capability Maintenance Capability Quality Test Capability Inventory Capability 9
ISA 95 Enterprise Control Systems ERP, CRM, Planning Increasing speed of communication 2 PLC/SCADA 1 Visions system, Motor 0 - Product Product 10
MESA 2011 11
Maintaining quality during manufacturing Machine Calibrated? Correct method or recipe selected? Operator trained? Meeting build plan? Correct materials used? Any open NCs or CAPAs? Material within specification? 12
Fully integrated MES 13
Accidental Architecture PLM LIMS Integration grown haphazardly over time. Integration protocols vary DB connection CIFS (File) TCP/IP Web Services Failure modes vary Variable levels of detection Variable levels of recovery Increased complexity Increased cost Increased skill and knowledge base MES n(n-1)/2 Point to Point ERP CAPA 14
Messaging Bus & SOA Planned integration Use common middleware solutions: Web Methods, BizTalk, Tibco, Fusion etc. Integration protocols Isolate protocols from source and target Failure modes Can be retrieved from messaging queue Can utilize BPM MES LIMS Messaging backbone PLM CAPA ERP Decreased complexity Single view of integration n=5 15
Integration Patterns & Pit falls PLM LIMS MES DB MES ERP Tightly coupled integration (direct table access) Business processes vulnerable to changes in MES schema Loss of schema control MES DB MES ESB Adaptors PLM LIMS ERP Loose coupling Protect the MES Schema 16
Publish and Subscribe The Pub/Sub model allow meta data to be used to selectively route traffic PLM Publish New Product definitions Subscribe to none CAPA ESB New Product definitions New Product definitions MES ERP Subscribe to 1 Subscribe to all 17
VETO Pattern Validate Enrich Transform Operate PLM ERP ERP XML Transform MES XML MES Validate Middleware Errors caught up stream Source & Target structures are decoupled System appropriate data 18
Inventory Management MES integration Requirements Update Lot Qty Update Lot Location Update Lot Status Update Issuance Record MES Consider a single interface for multiple transactions Consider message structure to support the interface Name/Value pairs Consider published standards 19
Shop floor integration Protocols TCP/IP OPC CIFS/File ODBC Input from MES Recipe ID/Product data Processing parameters Input to MES Processing results Pass/Fail Processing characteristics Challenges to traditional standards with Life Sciences tools Standards not established eg SECS/GEM 20
MES to DCS integration Production Schedule Production Performance ERP MES Detailed Production Schedule Product Tracking Product Performance Analysis Product Definition Production Dispatch Product Data Collection Data Historian Level 1-2 Production Execution Data Historian Off load large data sets to appropriate tool set Focus MES on active operations 21
Plan for the future Avoid tightly coupled interfaces Data coupling Process coupling Protocol coupling Right tools for the job ISA95 Reusable services Canonical data models 22
Questions? 23
Appendix 24
References ISA 95 Enterprise control systems ISA88 Batch manufacturing MESA.org APICS Supply chain basics 25
Decoupled/VETO Pattern - Example Validate Enrich Transform Operate Enterprise e-com e-com1 e-com2 ERP1 ERP2 Custom Design Content ERP XML Validate Transform Middleware MES XML ERP origin is added to Work Order Additional enrichment Metadata of source system MES is agnostic of ERP MES 26
Shop floor integration Reusability within Camstar Transaction ExportInfo Transport Transform Operate ExportInfo Transaction Resource Transport Config Transform Target Specific format 27