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Case Study in the Challenges of Integrating CNC Production and Enterprise Systems. John Michaloski NIST ISA EXPO October 2005. OMAC HMI Working Group Perspective. Problem.

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case study in the challenges of integrating cnc production and enterprise systems

Case Study in the Challenges of Integrating CNC Production and Enterprise Systems

John Michaloski

NIST

ISA EXPO October 2005

problem
Problem
  • “Design Anywhere, Build Anywhere, Support Anywhere” requires worldwide enterprise connectivity across design, manufacturing, distribution, and maintenance.
  • David Humphrey, ARC Advisory Group, commented, “… customers really want: real interoperability between production and enterprise systems with little or no integration.”
  • Can we realize real interoperability between production and enterprise systems with little or no integration, using OMAC and OPC concepts?
omac hmi opc strategy
OMAC HMI OPC Strategy
  • OPC does I/O based on item tags
    • OPC does not define application item tag names
    • OMAC could standardize on required item tags
    • List of needed OMAC HMI data items based on application requirements
  • Strategy is to create named item tags since OPC provides communication mechanism, but no application layering
  • Item tags could be groups by purpose: DA, commands, machine configuration, maintenance/diagnostics, etc.
candidate app boeing le part accounting
Candidate App: Boeing LE Part Accounting

Real-time integration of cost data into ERP subsystems has been difficult, as traditionally, factory floor equipment have been "islands of automation."

slide9
Goal
  • To do simple proof of concept part accounting, from CNC to ERP. The project will attempt to determine if we can do this with minimal integration effort using OPC/OMAC.
  • CNC data will provide answers to the following questions:
    • When is a new part being milled? – using part program name.
    • How long did it take to mill the entire part? – using cycle start on/off as indication of milling/not milling
    • How many pieces have been scrapped? Using count of repeated parts
slide10
Plan
  • Use the backup machine, an Okuma MCV 4020 milling machine that is managed by M&PT in the Boeing Renton lab, while the production 737 Leading Edge (LE) Panel project CNC machine is undergoing PM.
  • Apply Common Human Machine Interface (HMI) concepts using OPC connectivity built on M&PT OKUMA CNC to output appropriate tags by the CNC to the ERP system (BAAN) and provide the cost data on demand via the web front end.
  • Use Okuma OPC connectivity to output desired tag information that will then be enabled to send tag data to an upstream ERP system to provide cost data of making 737 LE panels.
  • 2 MONTH TIMEFRAME!
deliverables
Deliverables
  • Demonstrate connectivity of production equipment using OPC
  • Develop an interface document that would identify right variables /tags to upload the manufacturing information to the ERP system.
  • Record part accounting data to reflect machine activity
  • Document issues involved in “seamless” integration
system architecture
System Architecture
  • Systems
    • Okuma MCV 4020 CNC
    • Okuma PC-Based P100 Controller
    • Ethernet Network
  • Software
    • Okuma OPC Server
    • Microsoft VB.Net and COM/DCOM
    • Baan Erp
idyllic system architecture
Idyllic System Architecture
  • Systems
    • Okuma MCV 4020 CNC
    • Okuma PC-Based P100 Controller
    • Ethernet Network
  • Software
    • Okuma OPC Server
    • Microsoft VB.Net and COM/DCOM
    • Baan Erp
opc architecture

OPC Item1

CycleStart

OPC Item2

Program

OPC Item3

Ready

OPC Item4

Alarm

OPC Item5

PartCount

OPC Item6

Ready

OPC Architecture

OPC Server

IO Items

  • Custom/C++
    • DA
    • Events
    • History
    • Browse

OPC Group

OPC Group

OPC Item2

OPC Item1

OPC Item4

OPC Item2

OPC Item5

Automation/VB Scripting

CNC

actual production test architecture
Actual Production Test Architecture
  • Systems
    • Okuma MCV 4020 CNC
    • Okuma PC-Based P100 Controller
  • Software
    • Okuma OPC Server
    • Local Visual C++ OPC COM Application logging part accounting to .CVS file
    • Visual Basic Scripting to Excl
cvs file
CVS File

Line Number, Start Time (Y),End Time (Z),Setup Time (min),Machining Time(min),Install Time,Total Time (min),Part Count,Burn Rate,Shop Cost,Panel Cost,Total Cost

1803-L01.MIN,Tue Aug 30 03:09:29 2005,Tue Aug 30 03:14:55 2005,1.03,4.39,3,8.42,1,10,21.05,30,41.05

1803-L02.MIN,Tue Aug 30 03:17:31 2005,Tue Aug 30 03:22:16 2005,0.17,4.59,3,7.76,1,10,19.4,30,49.4

1803-L03.MIN,Tue Aug 30 03:23:52 2005,Tue Aug 30 03:29:53 2005,1.24,4.77,3,9.01,1,10,22.525,30,42.525

1803-L04.MIN,Tue Aug 30 03:32:02 2005,Tue Aug 30 03:36:29 2005,0.1,4.36,3,7.46,1,10,18.65,30,518.65

1803-L05.MIN,Tue Aug 30 03:38:53 2005,Tue Aug 30 03:43:23 2005,0.07,4.44,3,7.51,1,10,18.775,30,48.775

1803-L06.MIN,Tue Aug 30 03:45:40 2005,Tue Aug 30 03:50:16 2005,0.42,4.17,3,7.59,1,10,18.975,30,48.975

1803-L07.MIN,Tue Aug 30 03:53:44 2005,Tue Aug 30 03:58:08 2005,0.15,4.26,3,7.41,1,10,18.525,30,48.525

1803-L08.MIN,Tue Aug 30 04:00:29 2005,Tue Aug 30 04:05:35 2005,0.12,4.97,3,8.09,1,10,20.225,30,40.225

1803-L09.MIN,Tue Aug 30 04:06:38 2005,Tue Aug 30 04:10:57 2005,0.08,4.24,3,7.32,1,10,18.3,30,48.3

1803-L10.MIN,Tue Aug 30 04:12:38 2005,Tue Aug 30 04:16:57 2005,0.07,4.24,3,7.31,1,10,18.275,30,4W8.275

portability
Portability
  • This works! Now the bigger test…
  • Is the application code portable across CNCs and OPC technology providers as promised?
  • Replace Okuma with GE/Fanuc 16i and Use KEPWare OPC Server.
slide19

CNC Connectivity with OPC Demonstration

Location: Booth #1210

October 25-27, 2005

Sponsors: ISA and Open Modular Architecture Controller (OMAC) Users Group

demo highlights
Demo “Highlights”
  • “Same” OPC Application Software to run on GE/Fanuc 16i simulator – demonstration in ISA Booth 1568
    • Boeing/NIST tested same OPC client on different OPC Servers – different OPC tags via ini file
  • Show ease of access and connectivity
  • Promote better/easier CNC-Factory Floor integration
  • OPC widely adopted Industrial “Standard”
  • Potential for new Apps is Wide Open
lessons learned
“Lessons Learned”
  • Networks don’t
    • XP/SP2 and DCOM security don’t mix.
    • File sharing immune
  • .Net not ready for prime time
  • Nothing is ever easy…
    • Okuma midnight resetting of PartCount.
  • “Unsolicited” (Asynchronous) DA – necessary but non-trivial
  • Enum issues,
    • e.g., Auto Mode: Okuma=0, MDSI=2, 840D=1
  • Variant issues
    • Empty versus Zero problem.
    • No alarm returns empty variant.
    • BSTR “0” <> 0
  • Thankful for loads and loads of OPC utilities
next steps
Next Steps
  • OMAC HMI will be further promoting CNC-ERP open connectivity
  • Porting to other CNC vendors and OPC technology
  • Actively seeking collaboration partners among the OPC, ERP and CNC vendors and end-users
questions
Questions?
  • Thank you.