Development of Holonic Manufacturing Execution Systems

HolonicManufacturing Execution SystemFan-Tien ChengInstitute of Manufacturing EngineeringNational Cheng Kung UniversityTainan, Taiwan, R.O.C.Oct. 7, 2006Institute of Manufacturing Engineering, NCKU1

Outlines Introduction Basic Foundations Development of Holonic Manufacturing Execution Systems Development of WIP Holons Implementation and System Integration Summary and ConclusionsInstitute of Manufacturing Engineering, NCKU2

Outlines Introduction Basic Foundations Development of Holonic Manufacturing Execution Systems Development of WIP Holons Implementation and System Integration Summary and ConclusionsInstitute of Manufacturing Engineering, NCKU3

Introduction Background Motivation and PurposesInstitute of Manufacturing Engineering, NCKU4

IntroductionManufacturing Objectives• Cost Reduction• Cycle-Time Reduction• Yield Improvement• Empowerment• Agility• WIP Visibility• Asset Utilization• On-Time Delivery Failure recovery Security certificationInstitute of Manufacturing Engineering, NCKU5

Background - MES FrameworkIntroductionApplication 1ApplicationsOtherComponentSchedulerDesignPattern BSystemManagementDesignPattern AEquipmentManagementDesignPattern ALaborManagementDesignPattern AMaterialManagementDesignPattern AComponentsMESFrameworkObject Request BrokerCORBAInfrastructureObjectServicesCommonFacilitiesInstitute of Manufacturing Engineering, NCKU6

Motivation and Purposes -IntroductionCharacteristics of Holonic Manufacturing Systems•Intelligence•Autonomy•Cooperation•Reconfigurability•ExtensibilityInstitute of Manufacturing Engineering, NCKU7

IntroductionMotivation and Purposes -Deployment Diagram for Holonic Manufacturing Execution SystemsDataWarehouseShop-FloorHolonWIPHolonSchedulingHolonMaterialHandlingEquipmentHolonEquipmentHolonRobotAS/RSAGVInstitute of Manufacturing Engineering, NCKU8

Outlines Introduction Basic Foundations Development of Holonic Manufacturing Execution Systems Development of Scheduling Holons Development of WIP Holons Implementation and System Integration Summary and ConclusionsInstitute of Manufacturing Engineering, NCKU9

Basic Foundations Holon UML CORBA MES Framework Development Procedure for OO SystemsInstitute of Manufacturing Engineering, NCKU10

Basic Foundationsrules for external behaviorSubordination to wholeCo - operationwith peersSuper - ordination to parts(sub - holons)co - operationCo - ordinationwith environmentHolonco - operationco - operationHolon boundaryinternal structure & rulesMaterialHolonsEquipmentHolonsScheduling HolonJob Holon_1Institute of Manufacturing Engineering, NCKU11Job Holon_2

Basic FoundationsUML (Unified Modeling Language) Use Case Diagram Class Diagram State Diagram Sequence Diagram Collaboration DiagramInstitute of Manufacturing Engineering, NCKU12

Basic FoundationsCORBA (Common Object Request Broker Architecture)Application Interfaces Domain Interfaces Common FacilitiesObject Request BrokerObject ServicesObject ImplementationOMG Reference Model ArchitectureClientDynamicInvocationClientIDLstubsORBinterfaceStatic IDLSkeletonsDynamicSkeletonInvocationBasic Object AdapterRepositoryIm plem entationInterfaceRepositoryORB coreInstitute of Manufacturing Engineering, NCKU13The Structure of a CORBA ORB

MES Framework ArchitectureBasic FoundationsApplication 1ApplicationsOtherComponentSchedulerDesignPattern BSystemManagementDesignPattern AEquipmentManagementDesignPattern ALaborManagementDesignPattern AMaterialManagementDesignPattern AComponentsMESFrameworkObject Request BrokerCORBAInfrastructureObjectInstitute of Manufacturing Engineering, Services NCKU14CommonFacilities

Outlines Introduction Basic Foundations Development of Holonic Manufacturing Execution Systems Development of WIP Holons Implementation and System Integration Summary and ConclusionsInstitute of Manufacturing Engineering, NCKU16

Development of Holonic Manufacturing Execution SystemsDevelopment Procedure for HMESCollect Domain Requirements and AnalyzeDomain KnowledgeHolarchy DesignConstruct Abstract Object ModelPartition Application Domain into ComponentsIdentify Generic FunctionsDevelop the Generic HolonDefine Holarchy MessagesHolarchy Framework of HMESInstitute of Manufacturing Engineering, NCKU17

Development of Holonic Manufacturing Execution SystemsDevelopment Procedure for HMESCollect Domain RequirementsSystem AnalysisAnalyze Domain KnowledgeModifyConstruct Abstract Object ModelPartition Application Domain intoComponentsIdentify Generic Functions amongFunctional HolonsDevelop Generic HolonHolarchy DesignDefine Holarchy MessagesModifyDefine Holarchy Framework of HMESDesign Functional Holons Based onGeneric HolonFunctional Holons Design and ImplementationConstruct ApplicationsApplication ConstructionInstitute of Manufacturing Integrate System Engineering, and Test ItNCKU18System Integration and Testing

System Analysis• Manufacturing Objectives shown in pp. 5.• Open Interfaces• Modularization• Distribution• Configurability• Interoperability• Maintainability Security Certification Failure RecoveryInstitute of Manufacturing Engineering, NCKU19

Holarchy Design -- Construct Abstract Object ModelFactoryAreaDataWarehouseSupport all objects toaccess data0...*0...*0...*0...*LaborMaterial Equipment WIPManages0...*LaborHolonManages0...*MaterialHolonManagesEquipmentHolonManages0...* 0...* 0...* 0...*WIPHolon0...* 0...* 0...* 0...*0...*0...*ControlsDispatches jobsShop-FloorHolonDispatchesordersSchedulingHolonInstitute of Manufacturing Engineering, NCKU20

Holarchy Design -- Partition Application Domain intoComponentsFactoryAreaDataWarehouseSupport all objects toaccess data0...*0...*0...*0...*LaborManagementComponentLaborManages0...*LaborHolon0...*0...*MaterialMaterialManagementComponentManages0...*MaterialHolon0...*0...*EquipmentEquipmentManagementComponentManages0...*EquipmentHolon0...*0...*WIPWIPManagementComponentManages0...*WIPHolon0...*0...*ControlsDispatches jobsShop-FloorManagementComponentShop-FloorHolonDispatchesordersSchedulingHolonScheduling ComponentInstitute of Manufacturing Engineering, NCKU21

Holarchy Design -- Identify Generic Functions amongFunctional HolonsIntelligence Mechanism‣Exception Detection‣Exception DiagnosisSearch Mechanism‣Collaboration‣ReconfigurabilityInstitute of Manufacturing Engineering, NCKUSecurity Mechanism‣Security Certification‣Data Encryption‣Data Decryption22

Holarchy Design -- Develop the Generic HolonRequirements of GHUse Case Diagram for GHSequence Diagram for Diagnosing ExceptionsClass Diagram of Generic HolonGeneric Holon Internal ArchitectureInstitute of Manufacturing Engineering, NCKU23

Holarchy Design -- Develop the Generic HolonRequirements of GHIt can construct the message backbone for cooperationand communication purposes.It provides the mechanism for security.It provides the ability of error diagnosis.It provides the ability of searching the desired services.It provides the ability of establishing a database servicefor information storage.Institute of Manufacturing Engineering, NCKU24

Holarchy Design -- Develop the Generic HolonUse Case Diagram for GHConstruct communicationbackboneFunctionalHolonSearch desired servicesUse security mechanismUse intelligencemechanismConnect to localdatabaseInstitute of Manufacturing Engineering, NCKU25Database

Holarchy Design -- Develop the Generic HolonSequence Diagram for Diagnosing Exceptions (OOA): Functional Holon: HolonKernel : HolonConfiguration: Database1: Send exceptions2: Diagnose exception3: Get extension rulesReturn errorlevel4: ReasoningInstitute of Manufacturing Engineering, NCKU26

Holarchy Design -- Develop the Generic HolonClass Diagram of Generic Holon (OOD)CORBAInterfaceInitializeORB()CreatObject()CloseObject()SetInterceptor()HolonKernelconstructCORBAORBSetInitialService()SetDBConnection()SetRegistration()SetEncrypt()SetDecrypt()SetExceptionTest()SetSearchData()usemanage/useuseSecurityMechanismValidate()Encrypt()Decrypt()retrieveLocalDatabaseConnection()RetrieveData()UpdateData()useInstitute of Manufacturing Engineering, NCKU27KnowledgeBaseSearchEngine()Diagnose()AddRule()Match()RuleFilter()Holon Configuration

Holarchy Design -- Develop the Generic HolonGeneric Holon Internal ArchitectureSecurityMechanismLocalDatabaseKnowledgeBaseHolonKernelCORBAInterfaceInstitute of Manufacturing Engineering, NCKU28

Holarchy Design -- Define Holarchy Messages• Fully-Automated Holarchy MessagesSequence DiagramCollaboration Diagram• Semi-Automated Holarchy MessagesSequence DiagramCollaboration DiagramInstitute of Manufacturing Engineering, NCKU29

Holarchy Design -- Define Holarchy MessagesFully-Automated Holarchy Messages - Sequence Diagram: External UserShop-FloorHolonSchedulingHolonAS/RSAGVRobotEMHolonWIPHolonData Warehouseplace an ordersave order inforamtiondispatch orderget WIP statusget item master, equipment status, and order statusshcedulingdispatch jobdispatch jobdispatch jobdispatch jobretrieve lot from AS/RStrack out (retrieving from AS/RS)return track-out resultupdate lot statussetup paremeter[if wrong lot] store wrong lot and retrieve the correct oneget BOM and recipemove lot to AGVtransport lot to equipmentLoop back if theorder was not done.Institute of Manufacturing Engineering, NCKU30track in (in equipment)return track-in result[if track in fail] move to next equipmentupdate lot status

Holarchy Design -- Define Holarchy MessagesFully-Automated Holarchy Messages - Sequence Diagram(Cont’d): External UserShop-FloorHolonSchedulingHolonAS/RSAGVRobotEMHolonWIPHolonData Warehouse[if track in fail] move to next equipmentnotify robot to pick up the lotmove lot to equipmentvalidate lotequipment start processupdate equipment statusfinish jobmove lot to AGVtrack out (in equipment)update lot statustrack out job donetransport lot to next stationmove lot to AS/RStrack in (storing in AS/RS)send storing informationupdate lot statusstore lot in AS/RSreport order doneorder doneInstitute of Manufacturing Engineering, NCKU31

Holarchy Design -- Define Holarchy MessagesFully-Automated Holarchy Messages - Collaboration Diagrammove lot to AGVorder donemove lot to AS/RSExternal Userplace an orderreport order doneShop-Floor Holondispatch orderScheduling Holonget WIP statusWIP Holondispatch job• track in• track outAS/RSdispatch job• return track-out result• send storing informationget item master, equipmentstatus, and order statusEquipmentManagement Holonget item master, BOM• get BOM nad recipe• update equipmentstatusfinish jobdispatch jobdispatch jobRobotAGVnotify robot to pick up the lot• return track-in result• return track-out result• track in• track outsave order informationupdate lot statusInstitute of Manufacturing Engineering, NCKU32Data Warehouse

Holarchy Design -- Define Holarchy MessagesSemi-Automated Holarchy Messages - Sequence Diagram: External UserShop-FloorHolonSchedulingHolonMaterialMoverLMHolon: EquipmentOperatorEMHolonWIPHolonDataWarehouseplace an ordersave order informationdispatch orderget WIP statusget item master, equipment status, and order statusschedulingdispatch jobif differentproduct[if different product] assign setup jobtransport lotassign equipment setup joblot arrivessetup equipmentget BOM and recipedo track-in jobscan barcodeInstitute of Manufacturing Engineering, NCKU33validate lottrack in

Holarchy Design -- Define Holarchy MessagesSemi-Automated Holarchy Messages - Sequence Diagram (Cont’d): External UserShop-FloorHolonSchedulingHolonMaterialMoverLMHolon: EquipmentOperatorEMHolonWIPHolonDataWarehousevalidate lottrack instart equipmentupdate lot statusequipment start processupdate equipment statusequipment job donedo track-out jobscan barcodetrack outupdate lot statustrack-out job doneLoop back if theorder was notdone.track-out job donetransport lot to next stationorder donereport order doneInstitute of Manufacturing Engineering, NCKU34

Holarchy Design -- Define Holarchy MessagesSemi-Automated Holarchy Messages - Collaboration Diagramorder donedispatch joblot arrivesExternal Usertrack out job doneMaterial Moverreport order doneplace an ordertrack out job doneassign setup jobdispatch orderequipment job doneShop-Floor HolonScheduling Holonget WIP statusWIP Holon• track in• track outget item master, BOMget item master, equipmentstatus, and order statusEquipmentManagement Holon• get BOM nad recipe• update equipmentstatus• setup equipment• scan barcode• start equipmentLabor ManagementHolon• assign equipment setup job• do track-in job• do track-out jobsave order informationInstitute of Manufacturing Engineering, NCKUupdate lot status35Data WarehouseEquipmentOperator

Holarchy Design -- Holarchy Framework of HMESApplication 1ApplicationsExchangeHolonSchedulingHolonShop-FloorHolonEquipmentHolonWIPHolonMaterialHolonFunctionalHolonsHolarchyG H G H G H G H G H G HObject Request BrokerCORBAInfrastructureObjectServicesCommonFacilitiesInstitute of Manufacturing Engineering, NCKU36

Outlines Introduction Basic Foundations Development of Holonic Manufacturing Execution Systems Development of WIP Holons Implementation and System Integration Summary and ConclusionsInstitute of Manufacturing Engineering, NCKU37

Development of WIP HolonsRequirements for WIP HolonsObject-Oriented AnalysisObject-Oriented DesignInstitute of Manufacturing Engineering, NCKU38

Development of WIP HolonsRequirements for WIP HolonReal-Time Update WIPTrack by Process of LotsProvide Information for Other HolonsProvide Information for UsersAbility of Accessing DBMSOpen InterfacesError RecoverySecurity CertificationInstitute of Manufacturing Engineering, NCKU39

Holarchy Messages of WIP HolonDevelopment of WIP HolonsScheduling Holonget WIP statusget BOM, item masterupdate WIP statustrack in,track outWIP Holontrack in,track outData Warehousereturn track-in resultreturn track-out resultreturn track-in result,return track-out resultInstitute of Manufacturing AS/RSEngineering, NCKU40AGV

Development of WIP HolonsUse Case Diagram for WIP HolonExternal UserCommon DatabaseGeneric EvaluatorTrack outTrack inProvide lot informationHandle ExceptionsInstitute of Manufacturing Engineering, NCKUUser41Login System

Development of WIP HolonsCreating New WIP Object (OOA): External User: WIP Manager : WIP : CommonDatabasecreate new WIPsgenerate new WIPsget BOMget item masterget order statusInstitute of Manufacturing Engineering, NCKU42

Regular Track in (OOA)Development of WIP HolonsWIP ManagerWIP: External Usertrack inFunctional Holonasks to track in.get specific WIPtrack inget BOM on Eq[if wrong Eq]send wrong Eq messagecheck BOM and process sequence[if wrong BOM]send wrong BOM message[if OK]send starting processing messagereturn track-in resultupdate WIP statusInstitute of Manufacturing Engineering, NCKU43

User Login System (OOA)Development of WIP Holons: UserUser InterfaceWIP Managerenter user informationsend user informationcheck user's authority[if granted] enable track-in functions[if granted] enable track-out functions[if granted] enable query functionsInstitute of Manufacturing Engineering, NCKU44

Development of WIP HolonsOOA-Stage Class DiagramGeneric HolonHolonKernelHolonConfigurationUser InterfaceWIP ManageruseRecovery Managermanage0...*WIPInstitute of Manufacturing Engineering, NCKU45

Development of WIP HolonsCreating New WIP Object (OOD): External User: WIPManager : WIP: BOM: ItemMaster: CommonDatabaseCreateNewWIPs(lotID,quality,count)WIP()NewVariables()get BOMConstructor ofWIP ClassNewVariables()get Item Masterget order statusInstitute of Manufacturing Engineering, NCKU46

Regular Track in (OOD)Development of WIP Holons: External User: WIPManager : WIPDoTrackin(Barcode, Station)Trackin(Barcode, Station)Returns TRUE iftrack-in is ok.Searches WIPby parametersSee SequenceDiagram of "Track in"Institute of Manufacturing Engineering, NCKU47

“Track in” Operation (OOD)Development of WIP Holons: WIPManager: UserInterface : WIP: CommonDatabaseget BOM on EqCheckBOM&PS ()ShowCheckResult ()Checks BOM andprocess sequence.[if this track-in is the last station]DeleteRepository(lotID)These operations happenwhen the track-in is on laststation.save WIP status[if this track-in is the last station]DeleteMe()Institute of Manufacturing Engineering, NCKU48

User Login System (OOD)Development of WIP Holons: User: UserInterface : WIPManager: SecurityMechanismenter user informationLogin(userID, password)SetRegistration(userID,password)Validate(userID,password )[if granted] EnableTrackin()[if granted] EnableTrackout()[if granted] EnableQuery()Institute of Manufacturing Engineering, NCKU49

Development of WIP HolonsOOD-StageClass DiagramCORBAInterfaceHolon ConfigurationSecurityMechanismretrieveLocalDatabaseInitialORB()CreatObject()CloseObject()Validate()Encrypt()Decrypt()Connection()RetrieveData()UpdateData()constructCORBAORBuseHolonKernelSetInitialService()SetDBConnection()SetRegistration()SetEncrypt()SetDecrypt()SetErrorTest()SetSearchData()manage/useuseuseKnowledgeBaseSearchEngine()Diagnose()AddRule()Match()RuleFilter()Generic HolonWIPManagerUserInterface+ Login()+ Trackin()+ Trackout()+ Query()- EnableTrackout()- EnableQuery()- EnableTrackin()- ShowCheckResult()- ShowTrackoutResult()- ShowQueryResult()+ CreateNewWIP()+ DoTrackin()+ DoTrackout()+ Query()+ SendException()- KillRepository()- ValidateID()- Recover()- SaveLog()manageuseRecoveryManager- ReConnectLDB()- TryConnection()- AlarmAGV()- AlarmASRS()- AlarmRobot()●●●BOM- NewVariables()use0...*WIPLotID : String = initvalBarcode : String = initvalStorageX : Integer = initvalStorageY : Integer = initvalQuality : Integer = initvalType : String = initvalStation : String = initvalBOM : Object = initvalItemMaster : Object = initvalOrderID : type = initvaluseItemMaster- NewVariables()Institute of Manufacturing Engineering, NCKU50- Trackin()- Trackout()- DestroyMe()- GetStructure()- CheckBOM&PS()

Development of WIP HolonsState Diagram ofWIP Object Life CyclestartCreate WIPdo: WIPCreate BOMdo: BOM:NewVariablesCreate Item Masterdo: ItemMaster:NewVariablesGetting order statusAll WIP initial information is collectedquery requesttrack-out requestDo track-outdo: TrackoutProvide WIP statusdo: GetStructureWait for request[not last process]track-inrequestDo track-indo: TrackinStore WIP statusto databaseStore WIP status toDatabase[last process]Delete the WIP repositorydo:WIP:DeleteRepositoryDelete WIPdo:DeleteMeInstitute of Manufacturing Engineering, NCKU51end

Development of WIP HolonsState Diagram ofWIP HolonEnd[if not granted]startUser Login the Systemdo: Login[if granted]Initiate CORBA Servicedo: SetInitialServiceReceives creating commandWIP Object Life Cycle[If last process finished]End[An Exception occurred]Diagnosedo: SetExceptionTestDo Recovery Operationdo: Recovery[Recovery failed]Send an Alarm[Recovery successful]Back to the lastoperation where theexception is occurredInstitute of Manufacturing Engineering, NCKUEnd52

Outlines Introduction Basic Foundations Development of Holonic Manufacturing Execution Systems Development of Scheduling Holons Development of WIP Holons Implementation and System Integration Summary and ConclusionsInstitute of Manufacturing Engineering, NCKU53

Implementation and System IntegrationSystem Deployment ArchitectureFunctional Holons Implementation ProcedureApplication Construction with System IntegrationInstitute of Manufacturing Engineering, NCKU54

Implementation and System IntegrationSystem Deployment ArchitectureDataWarehouseShop-FloorHolonWIPHolonSchedulingHolonMaterialHandlingEquipmentHolonEquipmentHolonRobotAS/RSAGVInstitute of Manufacturing Engineering, NCKU55

Implementation and System IntegrationFunctional Holons Implementation Procedure1. Generic Holon Development1Generic HolonDevelopment2. HMES Framework2Define FunctionalHolon Framework IDLidl2java3B-1Client Stub3A-1Server Skeleton3B-2ImplementFunctional HolonClient3A-2ImplementFunctional HolonServerjavacjavac3B-3Locate Servers ofother FunctionalHolons3A-3RegisterFunctional HolonServerjavac3. Functional HolonDevelopmentInstitute of Manufacturing Engineering, NCKU456Functional Holon Ready

Implementation and System IntegrationApplication Example for Getting WIP StatusScheduling HolonWIP HolonCommonDatabaseSH:SchedulingManagerSH:InformationManagerWH:WIPManagerWH:WIP: CommonDatabaseGetWIPStatus(lotID)Returns a structure ofWIPStatus including"Barcode", "lotID", "Station","Quantity", and "Type"Query(Barcode,lotID,Station)[if WIP exists]GetStructure()[if WIP doesn't exist]get WIP's recordInstitute of Manufacturing Engineering, NCKU57

Outlines Introduction Basic Foundations Development of Holonic Manufacturing Execution Systems Development of Scheduling Holons Development of WIP Holons Implementation Summary and ConclusionsInstitute of Manufacturing Engineering, NCKU58

Summary and ConclusionsComparisons between MES and HMESSummary and ConclusionInstitute of Manufacturing Engineering, NCKU59

Summary and ConclusionsComparisons between MES and HMESLegacy MESMES HMESFramework FrameworkArchitecture Centralization Distributed OO HolarchyOpen Interfaces No Yes YesModularization Low High HighInteroperability Low High HighConfigurability Low High HighCost High Low LowMaintainability Difficult Easy EasySecurity Certification No No YesFailure Recovery No No Yes*Legacy MES: Promis, WorkStream, etc.,Framework MES: SiView, FACTORYWorks, etc.,Institute of Manufacturing Engineering, NCKU60

Summary and ConclusionsPresent a new concept for developing nextgeneration Manufacturing Execution Systems.Provide a systematic procedure to developholonic manufacturing systems.Demonstrate the feasibility and capability ofHMES by designing and implementinga WIP Holon.Institute of Manufacturing Engineering, NCKU61

References[1] F.-T. Cheng, E. Shen, J.-Y. Deng, and K. Nguyen, "Development of a SystemFramework for the Computer-Integrated Manufacturing Execution System:a Distributed Object-Oriented Approach," International Journal of Computer IntegratedManufacturing, vol. 12, no. 5, pp.384-402, September/October, 1999.[2] F.-T. Cheng, C.-F. Chang, and S.-L. Wu, "Development of Holonic ManufacturingExecution Systems," Journal of Intelligent Manufacturing, vol. 15, no. 2, pp. 253-267,April 2004.Institute of Manufacturing Engineering, NCKU62

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