2. Type: Breakout | Track: Enterprise | Level: Intermediate
Solving Typical Enterprise MES Architecture with Sepasoft
Type: Breakout | Track: Enterprise | Level: Intermediate

3. AGENDA
About Us
New MES Solutions
Roadmap
Jason

4. About Us
Jason

5. ABOUT US The Basics Started creating MES modules for Ignition in 2010
Healthy year-over-year growth
Solutions are used in Batch, Discrete, and Continuous manufacturing environments
Provides MES solutions for Automotive, Pharmaceutical, Food and Beverage, Mining, Steel Industry, among others
Mixed HMI, SCADA, & MES
Jason

6. ABOUT US
Built on ISA-95
A standard for building enterprise manufacturing solutions
Developed to be applied in all industries and every type of process (batch, continuous, discrete, and repetitive)
Creates a consistent terminology that provides a foundation for supplier and manufacturer communications
Manufacturing Enterprise Solution Association (MESA)
Jason

7. New MES Solutions
Jason

8. NEW MES SOLUTIONS Functional Categories Ignition Perspective MQTT
OEE Light
Material Location
Business Connector
Enterprise 2.0
Jason

9. IGNITION 8.0 Perspective MES Component Upgrade
Production components (targeted for 8.0 release)
Remaining components (following 8.0 release)
Jason
This is exciting because now clients are not dependent on the JRE
Existing vision components will be supported for the foreseeable future.
Production components
Downtime table, timing chart, run director, schedule selections, ?

10. MQTT and OEE Common Problems Communication to Field Devices
Device protocols increase the load on the server
WAN outages cause gaps in OEE data
Higher network load
Security
On-prem Servers
Backups and system maintenance
Disaster recovery
Jason
Taking a look at OEE without MQTT there are some common pain points that exist.
Device protocols increase the load on the server
Communications with PLC devices using native protocols are based on a polling rate and the same data is read over and over.
The driver in Ignition must handle all of the minute details of theses communication and increases the load on the server.
It can be offloaded to another server but at a increased cost.
WAN outages cause gaps in OEE data
Events that occur during the WAN outage are simple lost.
Higher network load
The constant chatter to tens or even hundreds of devices requires more network bandwidth.
If a WAN and VPN is being used, then it is even more of a concern.
Security
Because the requests for data is initiated from the server, ports must be opened to the outside world.
Many of the legacy devices don’t have authentication and outsiders could read data from or, even worse, write data to the field devices.
Backups and system maintenance
It makes sense to centrally locate any servers we can to reduce costs.
Handling backups at a remote site is not fun.
Remote support is more difficult.
Recovering on-prem servers after a disaster takes longer and can affect production.

11. MQTT and OEE PLC Machine “1” PLC Machine “2” PLC Machine “3” PLC
Edge
Device
PLC
Machine “1”
Edge
Device
PLC
Machine “2”
Edge
Device
PLC
Machine “3”
Edge
Device
PLC
Machine “n”
MQTT Servers
Remote Factory
Jason

12. MQTT and OEE
MQTT DEMO
Tom

13. OEE Light Common Problems Reduced Requirement Scheduling is not needed
Work orders are not needed
Cost
Pilot cost
Very small facilities (limited equipment)
Jason
Reduced Requirements
Schedule and WO are not needed
Just basic functionality is need and the standard OEE version is and overkill
Cost
With OEE, ROI is sometime difficult to determine until it is tried and some results are collected. Kinda a catch 22
Some facilities are so small, they don’t need the bells and whistles.

14. OEE Light Features General Lightweight (can run on Ignition Edge)
Additional Factors (Limited to 5)
Shift control (Tag or Ignition Schedule)
Integrated Database
1GB (depending on system resources)
Backup Utility
OEE and Downtime
Supports multiple cells and cell groups under a single primary machine
All downtime detection methods supported
Jason
General
Can run on an Ignition edge device or full sized system.
Still can track data in addition to the OEE downtime data using additional factors.
Such as maintenance crew, building humidity, raw material vendor, etc.
It is just limited to 5 additional factors
Tag values or Ignition Schedule can drive the shifts.
Integrated Database
No need to install and configure a separate database.
Because of this it will include a separate backup utility.
OEE and Downtime
One line with multiple machines
Key reason, parallel cells, initial reason or simple machine state down time detection methods are all supported.
Even a mix of downtime detection methods.
For those who may not be familiar, the downtime detection algorithms are designed to determine the accurate reason the a line lost production.

15. OEE Light Feature Continued Analysis
Live Analysis (limited to 2 per line, cell group or cell)
Analysis Controller
Core Components
Downtime Table
Timing Chart
Chart components
Material Management
Mode and State Management
Value Editor
Jason
Analysis
Live analysis provide results to the minute.
We have a very optimized cache that can update analysis data when notable production events occur.
The Analysis Controller allow building customized dashboards.
Full support to correct or update past production data. Example, updating quality information a day or two after production.
Not everyone want this, but it is surprisingly common.
Core Components
All of the components that are needed for a simple OEE Downtime system are provided.
The price hasn’t been finalized so we can’t share that with you today, but it will be competitive with other low end low cost offerings available in the industry.
The difference between them is OEE Light will have far more features and capabilities.

16. MATERIAL LOCATION Common Problems Data Entry
More scanning, selections and typing by the operator
Entry errors
Lost Material
Moved without the system being updated
Poor location granularity
Accuracy
Wrong product
Incorrect trace results
Jason
Data Entry
Collecting the correct information about a production run such as lot numbers, material, quantities, work orders, etc. is typically a burden on the operator.
Requires time and is inefficient.
And prone to mistakes
Lost Material
Material get rearranged and it is not always updated in the inventory system.
Bays can be big and searching for specific material in the bay can be time consuming.
Accuracy
The correct production information was entered but the incorrect raw material is loaded into the machine.
Or correct raw material was loaded into the machine but the incorrect material was entered into the system.
Both of these lead to incorrect traceability results.

17. MATERIAL LOCATION Solution Real-time Material Tracking MES Integration
Efficiency
Find raw material faster
Auto lot detection
Less operator data entry
Accurate
Eliminates entry errors
Jason
Real-time Material Tracking
If real-time material tracking is used and it is integrated with the MES system, then most of these issues are solved
For example, when a forklift driver delivers raw material to a line, automatically the information is entered into the MES system with immediate feedback if it is the correct.
The material is selected with no scanning, no selections on a screen, no typing lot numbers and no errors.
Efficiency
Having a pinpoint location of a material lot eliminates to time searching.
Takes task off of the operators plate.
Accurate
Because it is removing the human factor, accuracy increases.

18. MATERIAL LOCATION
Web Services
MES Server
Wiser Server
Process: Chop Almonds
Material: Lot 2905A
Almonds
2905A
2:13 AM
Warehouse
Shipping
3:25 AM
Staging
Packaging
Batch
Processing
Tom
Typically, knowing where material lots are located within your manufacturing facility requires accurate operator input. This is one more detail that the operator must track, scan, or manually input in their already busy job.

19. MATERIAL LOCATION LOT LOCATION DEMO Tom
We have a mockup of this in action, but look for more enhancements to the MES modules for greater support in the near future.

20. MES BUSINESS CONNECTOR
Common Problems
Communications
Requires substantial customization and configuration
Data Translation
Typically scripting is used
Lack of exception handling
Difficult to managing data flow
Required Skill Sets
Knowledge of MES modules
Knowledge ERP / Web Services
Knowledge of Ignition / Python / SQL
Tom
A high percentage of MES systems integrate with ERP or other systems.
Today, integrating a Sepasoft MES system with ERP or other systems requires scripting.
In fact, integrating any MES system with ERP or other systems is painful.
Communications
Typically, something like web services, flat file, xDoc files, intermediary database, or middleware is used and it requires a lot of labor to implement.
Data Translation
Today this is done in scriptions - not pretty
Data flow and exception handling all done in scripting.
For example, processing a production order that refers to material requires lookups to see if the materials exists and is up to date in the MES system. If it is not then query the material details and add or update it in the MES system.
Again, not pretty.
Required Skill Sets
Really, a jack of all trades is needed to implement the integration.
This all adds up to higher cost to implement and maintain.
High TCO.

21. MES BUSINESS CONNECTOR
Features
Sequence Engine
BPEL - Business Process Execution Language
Translation
Interactive mapping UI
Supports B2MML
Connectors
Existing Web Services
SAP (Jco and XDocs)
More in the future
Tom
We looked at what it will take to solve these pain points when integrating with ERP or other systems.
And this is what we can up with:
Sequence Engine
A sequence engine to handle the data flow and exception handling.
It is based on BPEL that is similar to a flow chart and is easy to understand and learn.
Translation
A visual mapping tools that supports functions.
Function support concatenation, date conversions, etc.
We are already following the ISA-95 standard, so it made sense to support B2MML.
Connectors
It was a must for it to support various connection methods
Our existing Web Service module can be used as a connector for the Business Connector.
SAP and Web Services will be the first two with others to follow.

22. MES BUSINESS CONNECTOR
SAP
SAP Connector
ERP
Web Services
Other ?
Future ?
MES Core
Business Connector
Tom
If we expand the MES layer of the Ignition stack, we see the Business Connector sits on top of the MES Core.
Although it can be used without any other MES modules.
The business connector is where the sequence engine, translation layer, and other supporting functionality lives.
Then connectors sit on top of the business connector.
Initially, SAP and Web Services (which supports both SOAP and RESTful) will be available.
Later, additional connectors will be offered.

23. MES ENTERPRISE 2.0 Common Problems Data Synchronization
Requires substantial customization and configuration
Synchronization errors
WAN outages
Poor performance
Configuration and Management
Requires MES configuration at each server
Requires MES licensing to be done at each server
Lack of monitoring MES system
Disaster recovery is difficult
Security
Databases are open on VPN
Tom
We already talked about OEE Light intended for manufacturers with reduced requirements and now we are going to look at the other extreme.
Implementing MES for an enterprise.
Data Synchronization
Requires database replication or custom script to handle synchronization.
Difficult to make the correct data available to each production site.
Difficult to pass the actual production results back up the enterprise.
Difficult to pass along changes in a timely manner.
Bandwidth unfriendly
Configuration and Management
EAN can be used to manage windows and tags, but there is nothing to centrally manage the MES systems.
Difficult to manage licensing
Security
It is just a better security practice to no have databases connections private.

24. MES ENTERPRISE 2.0 What’s at Stake? Higher Cost
Increased implementation labor
Increased maintenance cost
Higher Risks
Lower reliability
Higher complexity
Lower security
Possible failure
Tom
All of these common problems lead to higher implementation cost, higher maintenance cost reliability issues or even failure
Higher Cost
High implementation hours
High ongoing support cost
Higher Risks
Higher complexity leads to higher risk and possibly even failure.

25. MES ENTERPRISE 2.0 Features Central Configuration
Equipment Hierarchy Configuration
Works alongside EAM
Data Synchronization
Gateway to gateway communications
Smart production data synchronization
Efficient / Scalable
Version control and logging
Contention resolution
Configurable production data storage
Artifacts
Tom
Central Configuration
Configuring equipment hierarchy (or production model) can be done at the enterprise server.
Optionally, each site or subsite can modify the equipment that is local.
Not matter where the changes are made, they are synchronized.
Because of requirement to have this synchronization feature, the production model is not longer stored in the Ignition project.
Instead it is saved in the database.
It works alongside EAM, but EAM is not required.
EAM is still used to manage the windows, scripts, tags, etc.
Data Synchronization
Utilizes the Gateway Network so it is gateways taking directly to gateways.
Not all data is synchronized to every MES server across the enterprise.
Only data that is pertinent to a production site or area is transferred.
Only production configuration data that is required is transferred. Not the whole enchilada.
And, only properties / values that changed are transferred.
The system is smart enough to initially transfer complete production data and then only transfer changes when they occur.
Optimized version control and change log detailing changes made to production data.
Automatic contention resolution performs last change across the enterprise is used.
Ability the set the duration to retain production data at each MES server.
Or not at making a MES server simple a relay of information.
Like custom properties, artifacts can be added to MES objects and are lazy loaded.
Artifacts support various data types including BLOBs.
BLOBs support items such as PDFs so work instructions can be saved with an object.

26. MES ENTERPRISE 2.0 Production Data Task Routing Results Redundancy Tom
SAP
ERP ?
Other
Production Data
Analysis
Task Routing
Backup
Redundancy
Enterprise
Results
Site 1
Site 2
Processing
Packaging
Processing
Packaging
Machine X
(OEE Light)
Tom
Using the Ignition Gateway Network to pass data from gateway to gateway. No more gateway to database.
Production orders are passed down to the appropriate sites, areas or machines.
The production results are then passed back up to the enterprise server.
Each MES server can be configured for what data to retain and for how long.
Redundancy can be used at the enterprise or any other server in the MES enterprise architecture.
Our existing task routing can also be set up at any level.
The OEE Light version covered earlier also integrates into this architecture.
The best part is any portion of this MES hierarchy can be in the cloud.
This can be used for disaster recover and restore of production data is automatic.

27. EARLY PREVIEW Tom What I’ll be demonstrating is…
ERP
MES Business Connector
Web Services
Enterprise
Site 1
Site 2
Processing
Packaging
Tom
What I’ll be demonstrating is…
Enterprise using the Enterprise Module
Communicate with and ERP system using the MES Business Connector and Web Services Modules
Receive production orders from ERP system
Which are processed and show in the schedule
And are automatically passed down to the appropriate production areas where they can be run
The results can be analyzed at the production area
But are also automatically passed up the enterprise to the site and enterprise levels to appear in analysis

28. SUMMARY Summary Support for Ignition Perspective
Enhanced Plant Floor to Business System Communications
More Scalability
Location Tracking
Enhanced Enterprise Management
Tom
Support for Ignition Perspective
Production components followed by the remaining.
Finally, were not dependent on the Java Runtime for the clients.
Enhanced Plant Floor to Business System Communications
MQTT Integration at the bottom
Communications between MES gateway servers in the middle
Business connector at the top
More Scalability
From OEE Light for basic systems to full blown enterprise and everything in between.
Location Tracking
Support tracking the exact location from material lots to supplemental equipment.
And, how that helps the operator and is more accurate.
Enhanced Enterprise Management
Centralized MES license management.
Production data synchronization.
Basically, we are committed to changing the status quo of the effort it takes to implement MES by solving the typical pain points and reducing the implementation cost.
Typically, the implementation cost is 2.5 to 3.5 times the cost of the MES software.
We want to see that reduced and also see the risks associated with implementing MES reduced.
There just has to be a better way than what the last decades has offered.

29. Roadmap
Tom

30. ROADMAP Development Roadmap 2019 2020 Maintenance Management Batch
Perspective
Phase I
Perspective
Phase II Q1 Q2 Q3
2019
2020
Tom
The good new is we have more than doubled our development staff from ICC last year.
The MES Business Connector and MES Enterprise 2.0 modules are targeted to be in release candidate in January.
OEE Lite is targeted for end of Q1
The initial Perspective components are targeted for the same time as Ignition 8.0
Followed by the remaining components late Q2
We have actually developed the core PFC (Process Functional Chart) engine that is used for Batch and it is targeted to be fully complete Q1 of 2020.

31. Questions? MES Design Consultants MES Modules Jason Coope, PMP
Business Connector
Joseph Dolivo
x600 | x600
MES Account Executive
Vincent Arespacochaga
x113
Inductive Automation