RFID-enabled Automation in Support of Factory Integration Robin Qiu, Ph.D. Penn State, USA Email:
[email protected] 1
ControlGen’s Real Time Visibility Solution
http://www.controlgen.com
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Point-of-care Service Scenarios
Service-oriented Community/Society • Fast
Google?, or Yahoo!?
(real time) • Accurate • Easy to use • Cheap (Standard) 3
Point-of-need Service Scenarios Supply Supply chain chain management: management: Google?, Tracking and Tracking and Control Yahoo!?, Control
Or ? “A crisis management team responds to a chemical “A crisis management team responds to a chemical spill spill by by using the • Fast using local local weather weather and and soil soil models models to to estimate estimate the spread spread of impact based (real time) of the the spill, spill, determining determining the theSS3: impact based on on population population a truck loaded SS1: a traveler location as well as geographic features as rivers and with commodity thatsuch • Accurate location as well as geographic features such as rivers and needs assistance. needs specific attention. water plan • Easy water supplies, supplies, creating creating aa short-term short-term mitigation mitigation planto use SS2: anon overturned truck loaded (perhaps chemical reaction models), and taking • Cheap (perhaps based based on chemical reaction models), and taking with hazardous chemicals. emergency emergency response response personnel personnel by by planning planning and and (Standard) coordinating evacuation, notifying coordinating evacuation, notifying hospitals, hospitals, and and so so forth.” forth.” Service-oriented Community/Society “The Anatomy of the Grid” by Foster, Kesselman, and Tuecke “The Anatomy of the Grid” by Foster, Kesselman, and Tuecke
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Contents
Can RFID help? How? Enterprise Service Computing? RFID: Value Proposition for Factory Integration?
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Contents
Can RFID help? How? Enterprise Service Computing? Can Grid Computing help?
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RFID Tag
Copyright © http://www.scs-mag.com/reader/RFID_Edge/index.htm
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RFID Reader
Copyright © http://www.skyetek.com, www.roxan.co.uk/electronic/ images/333-3.html, www.ti.com, http://www.nokia.com/
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Bar Code
Bar Code A UPC is created using a 12-digit numeric sequence scheme. A series of light and dark lines are used to represent a UPC code, while a human readable numeric equivalent is given together with the standard symbol. An example of a barcode looks like 0.03456.89234.6 Numbering System Character.Enterprise ID Number.Serial Number (Model).Modulo check character
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EPC
Electronic Product Code (EPC) An EPC is created using a 96-bit numbering scheme. It consists of an 8-bit header and three data partitions, i.e., 02.0006A66.56271F.0003476AB 8 bits.28 bits.24 bits.36 bits Header.Enterprise.Product.Serial Number “The 96-bit EPC provides unique identifiers for 268 million companies. Each manufacturer can have 16 million object classes and 68 billion serial numbers in each class, more than enough to cover all products manufactured worldwide for years to come.” 10
EPCglobal Architecture Framework
© EPCglobal Inc™
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EPCglobal Network: 5 Components
© EPCglobal Inc™
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The EPCglobal Network real-time object movement data Potential Benefits
© EPCglobal Inc™
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The EPCglobal Network™ Demonstration
Product Authentication
Gillette (along with solution providers Sun Microsystems and VeriSign, and trading partner Wal*Mart) demonstrated how a missing or mis-delivered Venus Case could be identified and re-associated with its order.
New Product Visibility
Procter & Gamble (P&G), solution providers TIBCO, IBM, VeriSign, and retailer Wal*Mart demonstrated how suppliers and retailers could utilize the EPCglobal Network to gain visibility into the store sales floor and backroom.
© EPCglobal Inc™
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Typical Example: DOD Logistics Physical Physical World World
Tagged Item
Tagged Container •• Fast Fast (global (global real real time) time) •• Accurate/precise Accurate/precise •• Easy Easy to to use use •• Cheap Cheap (Standards) (Standards)
Tagged Item 15
Wal-Mart's Supply Chain
•• Business Business Dynamics Dynamics •• Fast Fast (global (global real real time) time) •• Accurate/precise Accurate/precise •• Easy Easy to to use use •• Cheap Cheap (Standards) (Standards) Source: Teamsters, "Wal-Mart Organizing Update," Warehouse Newsletter (August 2000).
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The EPCglobal Network: Viable Solution?
“Indeed, behind the scenes, the application is making use of the EPCglobal Network to direct it towards whichever resource is required at any given time. The EPCglobal Network itself is responsible for knowing where to point an application looking for information based on a particular EPC or class of EPCs. Similar to the Internet, the EPCglobal Network is continuously updated, and it will know within 60 seconds when EPC-tagged products have arrived and been read at various locations, whether these are manufacturers, retailers or distribution centers.” © EPCglobal Inc™
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EPC & GIC & RFID
Global Identification Code (GIC) When an EPC is used as an object identifier, A GIC consists of an 8-bit header and four or more data partitions, i.e., 02.0006A66.56271F.0003476AB.IP.xxx 8 bits.28 bits.24 bits.36 bits.IP.options Header.Enterprise.Product.Serial Number.IP.xxx
Internet
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Real Time Visibility: Possible? How? Service Server
GPS
Internet Satellite
RFID reader writer
Products arrive at the gate of a facility.
Source: GL AgilityTech, Inc
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Global Real Time Visibility Solution? Container-level
Item-level Satellite
Tracing Server
GIC
C e llu la r Phone
Devices
Universal Data Appliance Protocol ? 20
Point-of-need Service Scenarios
SS2, SS3 SS1
SS1: a traveler needs assistance.
SS3: a truck loaded with commodity that needs specific attention.
SS2: an overturned truck loaded with hazardous chemicals.
Logical view of the IIS network Travel Information Service Server Point-of-need Information Server
Information linkage
Product Information Service Server
Delivering Just-in-time Intelligent Service? Service 21
Healthcare Delivery Networks
Service-oriented Community/Society
Delivering Global Real Time Service? Service 22
Distribution Center (Precise Location?)
1,150,000 sq. ft. WalMart Dry Goods Distribution Center Copyright © www.schwob.com/ projectswalmart.htm, www.siemense-dematic.us
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Value Proposition (Warehouse Example)
Cycle counting Operational Accuracy Labor saving Lower inventory Avoiding theft Reducing loss of sale Supply On Demand
Sell one, replenish one From an IT perspective, How can we support it? 24
Contents
Can RFID help? How? Enterprise Service Computing? Can Grid Computing help?
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Middleware is everywhere. Can you see it?
RFID tags are everywhere.
www.ibm.com
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fo
In
k ra rT
&
or ew m g in ck
Tr ac kin g
a Fr
te gr at io n
Key Elements to an RFID-enabled Networks
at gr te In
St an da rd sf or
& n io
Copyright © http://www.scs-mag.com/reader/2004/2004_04/logi0404/index.htm
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Catching Up the Changes
Copyright © www.nwc.com
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Business Aligning IT? Complex
Process Logic
Org IT Infrastructure
on i t a aniz
Dynamic 29
Competitive Enterprise?
Thomas J. Burke, Advisory Software Developer, Rockwell Software Incorporated
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A Complex System? hours
office-planning
min secs
operations
1 sec msec µ sec Multi-vendor Proprietary Complex information flows
controls Asynchronous Processing Multiple interfaces Mission Critical How to manage changes?
Thomas J. Burke, Advisory Software Developer, Rockwell Software Incorporated
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“Only the change is certain”
The business world is rapidly changing. The revolutionary technology of the Internet has led to the faster and more efficient interaction between customers, suppliers, and partners. A new trend is emerging where the performance and development of business processes is a collaboration between business partners (Internally and externally).
RFID EPC or GIC Networks? http://www.bpmn.org/Documents/NWG-2001-09-01R4%20Charter.pdf
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BPM Merging With SOA Services Business Process Layer:
BPM
BPMS Integration Platform
BPML/BPMN
Services Layer:
BPEL
(Web) Services SOAP, WSDL, UUDI …
Web Services Platform
Global Key Enabled Enterprise GIC Global Key? Modeling, Execution, Custom/ Office/ Service Computing? PeopleSoft SAP SAS Monitoring, Optimization Legacy Exchange Application Layer Modeling, Services Design, (Lifecycle management, Java/ C++ .NET/ CICS/ cross-function, end-toExecution, Monitoring, Mobile J2EE /Unix Windows OS/390 end business processes) OptimizationTechnology DBMS
MQ
Source: Eric Newcomer and Greg Lomow
LDAP
PKI
Layer 33
Contents
Can RFID help? How? Enterprise Service Computing? RFID: Value Proposition for Factory Integration?
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Controller Production Requirements I/O Channel
Controller Task List
Planner
System Status
Scheduler
Physical Configuration
I/O Channels
Executor
Physical System
Physical Model
System Model
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Control Hierarchy and Information Flow Entry
D/A
D/A
D/A
Exit Pla sma Oven
Overhead Track
Exception 3 r d Opt Wire Bonder
Wire Bonder
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A simplified process flow and identify hierarchy P1
InStage
Wafers in cassette.
WaferSaw
Physical Identifier: wafer cassette Cassette
DieAttach
RFID Tag DieAttach Cure WireBond Optical Inspection M ark Singulation Inspection
Pn
OutStage
Magazine Strip in magazine. (Typically each strip holds 6 ~ 10 d ies and each magazine stores 20 ~ 30 strips.) Each process has its own specification defining requirements Chips in on set up, tools, consumables, etc. tray.
Magazine
Physical Identifier: strip magazine Chip Chip Chip
Chip Chip Chip
Physical Identifier: indi vi dual chi p
RFID Tag
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A generic process model
Part state (Delivery In, M ove In, Processing, M ove Out, or Delivery Out), and other pertinent product and process information can be stored in an RFID tag. M ore information can be retrieved from its host application using the GIC technology.
1
2 1
3
4
5
2
4
3 5
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Synchronization using agents and GIC hierarchy Factory Information System (IP)
Office-level Information System
Office -level Information System Internet
Cell
MC MC
Different factory, facility or partner on the supply chain
MCS MCS: Material Control System
MC
MC: Machine Controller
2 1
4 3
5
GIC1
GIC2
GICn (GICs’ relations can be part of optional parameters stored in a tag or data source managed by host applications)
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A framework for the implementation of RFID-enabled factory integration
Planner, Scheduler, Dispatcher
Factory Database
ωu (Server)
Material control server
XM L
XM L Business Integration Engine (BIE) – Messaging-based Integration Middleware (XM L conversion, synchronization algorith ms, GIC event manager, GIC reference services, etc.) : RFID-enabled Integration Backbone XM L Cell Controller
Cell Controller
Dow nloadabl e
Dow nloadabl e
I nte r f ac e Engi ne
I nter f ac e Engi ne
Equi pment - ps eci f ic M odel
Equi pment - ps eci f ic Model
Equi pment - ps eci f ic M odel
Equi pment - ps eci f ic M odel
Equi pment - ps eci f ic Model
Equi pment - ps eci f ic M odel
Equi pment - ps eci f ic M odel
Equi pment - ps eci f ic Model
B US
Dow nloadabl e I nte r f ac e Engi ne
B US
Dow nloadabl e I nter f ac e Engi ne
B US
Dow nloadabl e I nte r f ac e Engi ne
B US
Dow nloadabl e I nte r f ac e Engi ne
B US
Dow nloadabl e I nter f ac e Engi ne
B US
Dow nloadabl e I nte r f ac e Engi ne
B US
Dow nloadabl e I nte r f ac e Engi ne
B US
B US
Cell Controller
Equi pment - ps eci f ic M odel
Process service controller
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Value Proposition
Standardized Data Exchange Ease of Factory Integration In Support of Fully Collaborated Supply Chain
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I really appreciate your attention and time.
Questions?
[email protected]
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