International Conference on Exploring Service Science – IESS 1.5
A Service Oriented Architecture for Total Manufacturing Enterprise Integration
Theodor Borangiu, Cristina Morariu, Octavian Morariu, Monica Drăgoicea, Silviu Raileanu, Iulia Voinescu, Anca-Alexandra Purcărea, Gheorghe Militaru
University Politehnica of Bucharest
[email protected]
IESS 1.5 Conference, February 4-6, 2015, FEUP, Porto
2
IESS 1.5, Porto, February 4-6, 2015
Summary
Introduction The Manufacturing Integration Framework Bus-oriented MIF integration Implementing issues Experimental results
3
IESS 1.5, Porto, February 4-6, 2015
Introduction
Service orientation - emerging nowadays at multiple organizational levels in enterprise business, leveraging technology in response to growing needs for business integration, flexibility and agility of manufacturing enterprises.
Challenges for companies - result from alterations in the global framework.
Competitive manufacturing - adapt to changing conditions imposed by the market: the greater variety of products, the possible large fluctuations in demand (products, batch sizes), the shorter lifecycle of products, and the increased customer expectations in terms of quality and delivery time are challenges that production companies have to deal with to remain competitive => need for flexibility
The control system - a critical element in the shop floor reengineering process, because any process/resource team change requires code modifications, implying the need for qualified programmers, usually not available in manufacturing SMEs.
4
IESS 1.5, Porto, February 4-6, 2015
Introduction
Solution: Agent-oriented and Holonic Manufacturing Execution Systems (HMES) used to:
Benefits of HMES: adaptability and flexibility when facing changes on the shop floor, and efficiency when using the available resources Current research: centralized batch scheduling systems (SS)
manage the correct and autonomous execution of a plan of activities efficiently respond to production changes and occurrence of unexpected disturbances
Drawback: lack of reactive capabilities and the inability to provide robust and efficient solutions in real time when disturbances occur (e.g., resource breakdown).
Horizontal integration: collaboration between centralized SS and distributed HMES (challenge to be faced)
5
IESS 1.5, Porto, February 4-6, 2015
The Manufacturing Integration Framework (MIF) Primary goal of Service Oriented Architecture (SOA) in the context of manufacturing enterprises: to align the business layer information flow with the technology specific information flow - the latter being partitioned on two layers:
(1) Management of customer orders; (2) Execution of customer orders (shop floor layer control).
The major components of SOA are: 1.
services;
2.
services bus;
3.
process choreography - composite applications;
4.
message transformation, mediation and routing;
5.
services registry.
6
IESS 1.5, Porto, February 4-6, 2015
The Manufacturing Integration Framework (MIF) Service-oriented business process integration for manufacturing: An emerging concept representing a business approach to SOA governance The Enterprise Service Bus (ESB) - a flexible connectivity infrastructure for integrating applications and services. ESB objectives: reduce the number, size and complexity of interfaces in a SOA. ESB actions between service requestor and provider:
Intelligent message routing between parties;
Conversion of transport protocols between service consumer and provider;
Transformation of message formats between service consumer and provider;
Handling business events from various sources.
7
IESS 1.5, Porto, February 4-6, 2015
The Manufacturing Integration Framework (MIF) Service-oriented business process integration for manufacturing From a SOA perspective, HMS – seen as a layered architecture (figure). Business Layer: Layer includes two main components - the offer request management module (ORM) and the customer order management module (COM). Manufacturing Execution Layer (MES): encapsulates the production scheduler (PH), production monitor (PM) and the product knowledge base. Shop Floor Layer: Layer represents the actual shop floor processes and structure. There are two types of active entities: intelligent products and shop floor resources.
8
IESS 1.5, Porto, February 4-6, 2015
The Manufacturing Integration Framework Service-oriented business process integration (design of COM, simulation)
Customer Order Management architecture
9
IESS 1.5, Porto, February 4-6, 2015
The Manufacturing Integration Framework Monitoring resource services for SS-dMES horizontal integration Client orders
Planned / planned + scheduled orders
System model / state
Process Knowledge Base • Product Holon (PH) • Aggregate product orders RSAM • Resource parameters • Operation accessibility
D
D Event-driven control Physical & informational interaction
Inter-OH Negotiation
Resource Holon
Order Holon
Machining Resource
Manipulation Resource
Resource Control Layer
ProductProduct- Transport carrier on-pallet Resource Intelligent Embedded Device OHs in execution
Resource status and parameters
System model update
Decentralized MES Layer
D
Product orders
Centralized MES Layer (IT)
Staff Holon • Configurable Batch Planning and Product Scheduling • Strategy Switch • OH traceability
Client reports
Physical Resources
2-layer architecture (SS, dMES) for semi-heterarchical shop-floor control
10
IESS 1-5, Porto, February 4-6, 2015
The Manufacturing Integration Framework Monitoring resource services for SS-dMES horizontal integration The proposed semi-heterarchical control architecture is based on the PROSA reference architecture (the basic holon structure -Product, Order, Resource) and extends it with: i.
Automatic strategy switching performed by a multifunctional Staff Holon entity and
ii.
Service orientation of operation scheduling and resource allocation by aggregating the information about the QoS performed by resources in a Resource Service Access agent (RSAM), replicated on several workstations (resource terminals) for fault tolerance.
RSAM offers two types of information for manufacturing resource service management:
Information related to the accessibility of services;
History of resources’ services (timeliness, quality, costs, …).
11
IESS 1.5, Porto, February 4-6, 2015
Bus-oriented MIF integration
The Enterprise Service Bus, Bus proposed as software architecture, has a set of key characteristics:
Message routing and control across enterprise components; Decoupling of various modules by asynchronous messaging, replacing point to point communication with the common bus architecture; Promote reusability of utility services, reducing the number of redundant services across the enterprise; Provide transformation and translation of messages to allow easy integration of legacy applications; Provide an engine for workflow execution.
Manufacturing Service Bus (MSB) based on ESB
Additional MSB characteristics: Event driven communication; Workflows; High number of messages; Message transformation and validation; Sync. and asynchronous communication; Message persistence; Intelligent message routing; Service directory; Distributed execution.
12
IESS 1.5, Porto, February 4-6, 2015
Bus-oriented MIF integration
Manufacturing Service Bus logical view
13
IESS 1.5, Porto, February 4-6, 2015
Bus-oriented MIF integration
The shop floor model consists in the following entities represented by their corresponding agents:
Product Holon (PH): agent representing the recipe needed to realize the product.
Order Holon (OH): a dynamic data structure initialized by the MIF layer, consists in the product execution characteristics associated with a customer order.
Resource Holon (RH): agent representing the capabilities of the physical resource (conveyor, robot, CNC machine).
Expertise Holon (EH): a data structure that records manufacturing execution and outcomes for each product type. EH is used during initial scheduling to assure an optimum allocation. In heterarchical mode, these EH data structures are used to decide the online resource allocation for each PH based on previous outcomes of similar operations (QoS, power consumption).
14
IESS 1-5, Porto, February 4-6, 2015
Bus-oriented MIF integration
The shop floor model consists in the following entities represented by their corresponding agents:
Product Database Database: agent that stores and retrieves data from a structured storage containing information about products and operations.
Resource Service Access Model (RSAM): agent that acts as a resource broker, where RHs can publish their state and capabilities. This information is used by OH(s) during execution.
Execution Monitoring Agent (EMA): centralizes OH states; it executes process monitoring at PH level, being responsible for generating periodic events that are sent through the Mediator Agent to the upper layer ESB and consumed by the Audit services. This activity enables the business layer to have real time data of the production schedule. This information can also be routed to the CRM module to enable customers to track the execution status.
15
IESS 1.5, Porto, February 4-6, 2015
Bus-oriented MIF integration
Business and shop-floor layers - MSB integration with Mediation Agent
16
IESS 1-5, Porto, February 4-6, 2015
Implementing issues
MIF implementation at MES level
17
IESS 1.5, Porto, February 4-6, 2015
Implementing issues
Resource and order integration in the HMES control architecture using JADE
18
IESS 1.5, Porto, February 4-6, 2015
Implementing issues
Software system controlling shop-floor processes in the dual HMES mode: SS-dMES
19
IESS 1.5, Porto, February 4-6, 2015
Experimental results
Comparative performance analysis of the hierarchical, heterarchical and semi-heterarchical types of control strategies in the presence of resource failure.
Experiment A batch of 200 orders was executed in 3 situations (figure): Experiment: 1 – pure hierarchical planning with perturbation where orders are replanned and rescheduled at centralized MES level (with production stop), 2 – semi-heterarchical operation consisting of hierarchical to temporary heterarchical commuting with recovery of hierarchical mode: when a resource failure occurs, the remaining orders are rescheduled on 2-time intervals: orders in execution are re-scheduled online while all remaining batch orders are re-planned and rescheduled offline at global level, 3 – hierarchical to permanent heterarchical commuting when a resource failure occurs.
20
IESS 1-5, Porto, February 4-6, 2015
Experimental results and conclusions
Comparison of makespan for different execution strategies
Conclusion The paper proposes a Service Oriented Architecture for Conclusion: Total Manufacturing Enterprise Integration used for supporting both the business and control operation of manufacturing systems.
21
Thank you !
