United States Department of Commerce National Institute of Standards and Technology Manufacturing Engineering Laboratory Intelligent Systems Division Case Study in the Challenges of Integrating CNC Production and Enterprise Systems John Michaloski NIST ISA EXPO October 2005

NIST Manufacturing Engineering Laboratory Intelligent Systems Division OMAC HMI Working Group Perspective

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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?

NIST Manufacturing Engineering Laboratory Intelligent Systems Division OPC Integration Technology

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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.

NIST Manufacturing Engineering Laboratory Intelligent Systems Division AxisSiemensFanuc (methods) Okuma AxisAbsolutePosition$AA_IM[X] /Channel/MachineAxis/actToolBaseP os cnc_absoluteOPC//Position/ActualPostion/ActualPositionAxis XX.Position AxisDistanceToGo$AA_DTEB[X] /Channel/State/acDteb[x] /Channel/GeometricAxis/progDistTo Go cnc_distanceOPC//Position/TargetPosition/TargetPositionAxis XX.Position AxisFollowingError/Nck/servoDataFl32[1]N/ANA AxisLabel$MN_AXCONF_MACHAX_ NAME_TAB[n] /Channel/MachineAxis/name cnc_rdsvmeter() label OPC//Position/TargetPosition/TargetPositionAxis XX.Name AxisLoad/Channel/MachineAxis/aaLoad[]cnc_rdsvmeterOPC/Position/TargetPosition/TargetPositionAxis XX.Load Data Point Mapping

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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."

NIST Manufacturing Engineering Laboratory Intelligent Systems Division

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

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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!

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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

NIST Manufacturing Engineering Laboratory Intelligent Systems Division OPC Server OPC Group OPC Item1 OPC Item2 OPC Item5 OPC Group OPC Item2 OPC Item4 Automation/ VB Scripting Custom/C++ DA Events History Browse CNC OPC Architecture IO Items OPC Item1 CycleStart OPC Item2 Program OPC Item3 Ready OPC Item4 Alarm OPC Item5 PartCount OPC Item6 Ready

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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: ,Tue Aug 30 03:14: ,1.03,4.39,3,8.42,1,10,21.05,30, L02.MIN,Tue Aug 30 03:17: ,Tue Aug 30 03:22: ,0.17,4.59,3,7.76,1,10,19.4,30, L03.MIN,Tue Aug 30 03:23: ,Tue Aug 30 03:29: ,1.24,4.77,3,9.01,1,10,22.525,30, L04.MIN,Tue Aug 30 03:32: ,Tue Aug 30 03:36: ,0.1,4.36,3,7.46,1,10,18.65,30, L05.MIN,Tue Aug 30 03:38: ,Tue Aug 30 03:43: ,0.07,4.44,3,7.51,1,10,18.775,30, L06.MIN,Tue Aug 30 03:45: ,Tue Aug 30 03:50: ,0.42,4.17,3,7.59,1,10,18.975,30, L07.MIN,Tue Aug 30 03:53: ,Tue Aug 30 03:58: ,0.15,4.26,3,7.41,1,10,18.525,30, L08.MIN,Tue Aug 30 04:00: ,Tue Aug 30 04:05: ,0.12,4.97,3,8.09,1,10,20.225,30, L09.MIN,Tue Aug 30 04:06: ,Tue Aug 30 04:10: ,0.08,4.24,3,7.32,1,10,18.3,30, L10.MIN,Tue Aug 30 04:12: ,Tue Aug 30 04:16: ,0.07,4.24,3,7.31,1,10,18.275,30,4W8.275

NIST Manufacturing Engineering Laboratory Intelligent Systems Division Excel File

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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.

NIST Manufacturing Engineering Laboratory Intelligent Systems Division CNC Connectivity with OPC Demonstration Location: Booth #1210 October 25-27, 2005 Sponsors: ISA and Open Modular Architecture Controller (OMAC) Users Group

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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

NIST Manufacturing Engineering Laboratory Intelligent Systems Division “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

NIST Manufacturing Engineering Laboratory Intelligent Systems Division 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

NIST Manufacturing Engineering Laboratory Intelligent Systems Division Questions?  Thank you.