SIMATICIT TechnicalOverview

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Preface Table of Contents Overview Production Information Management
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SIMATIC IT 6.3 SP1
SIMATIC IT Production Modeler SIMATIC IT Product Definition Manager SIMATIC IT Material Manager
Technical Overview
Function Manual
SIMATIC IT Production Order Manager SIMATIC IT Personnel Manager SIMATIC IT Shift Calendar SIMATIC IT Data Integration Service SIMATIC IT Client Application Builder SIMATIC IT Historian
Edition 01/2008
A5E01140770-01
Guidelines
This manual contains notices intended to protect the products and connected equipment against damage. These notices are graded according to severity by the following texts: Caution Indicates that if the proper precautions are not taken, this can result into property damage. Notice Draws your attention to particularly important information on handling the product, the product itself or to a particular part of the documentation.
Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG Automation and Drives Postfach 4848 90437 NRNBERG GERMANY
A5E01140770-01 01/2008
Copyright Siemens AG 2008 Technical data subject to change
Preface
Purpose
This Function Manual explains the fundamental concepts, features and functionalities provided by SIMATIC IT Production Suite. Important This guide does not intend to describe how to use and configure each SIMATIC IT component. For more information concerning the configuration and use of the components see the related help online documentation. (Start > SIMATIC > SIMATIC IT Documentation).
Basic knowledge required

This guide is intended for SIMATIC IT users who are responsible for system configuration, such as application managers and system integrators (consultants). To be able to understand the concepts and examples discussed in this guide, the reader should at least have taken the SIMATIC IT Training.
Where is this manual valid?

This manual is valid for release 6.3 SP1 of SIMATIC IT.
Readme
The installation includes a readme file, which contains information on upgrade procedures and compatibility with previous releases. This file is supplied both in standard text (Readme.wri) and in Acrobat PDF (Readme.pdf) format. This file is available in folder \ReleaseNotes of the setup DVD and is available from the shortcut Start > SIMATIC > SIMATIC IT Documentation.
Online help
The online helps of SIMATIC IT, which is integrated in the software, complements this Function Manual and provides you with detailed support for using the software. These helps are all available online from the shortcut Start > SIMATIC > SIMATIC IT Documentation. The help system consists of: The Contents and Index command on the Help menu to open the online help window, from which you can choose the topic of interest. You can search for the desired information, using the table of contents or the index A context-sensitive help that offers information on the current context, for example, an open dialog box or an active window. You can open the contextsensitive help by clicking the Help button in any dialog box.
SIMATIC IT V6.3 SP1 A5E01140770-01 iii
Preface A status bar that offers another type of context-sensitive help. It displays a short explanation for each menu command when the mouse pointer is positioned on the menu command. A brief explanation (ToolTip) for each icon in the toolbar when the mouse pointer is positioned on the icon for a short time.
Related documentation
The following documents contain information related to the content of this Function Manual: SIMATIC IT Configuration Manual SIMATIC IT Installation Manual SIMATIC IT Licensing Configuration Manual Best Practices Configuration Manual SIMATIC IT Application Deployment Configuration Manual KPI Management Configuration Manual Client Application Builder Concept Guide Client Application Builder Portal Startup Guide Client Application Builder Portal Developer Manual Client Application Builder Visual Composer User Manual Client Application Builder Good Programming Practice Developer Manual Data Integration Concept Guide Data Integration Service Tips and Tricks User Manual Historian Concept Guide Historian Data Recovery Management User Manual All these documents are available online from the shortcut Start > SIMATIC > SIMATIC IT Documentation.
Conventions
The table below describes the specific typographic conventions that are used throughout this manual:
Symbol/Convention Indicates...
E.g. Text in bold
Where examples are given. The names of menus, commands, dialog boxes and toolbar buttons and, in general, all strings (e.g. File menu; Save command). Shortcut keys, which permit rapid access to commands (e.g. CTRL+C). The names of keyboard keys (e.g. RETURN key).
KEY1+KEY2 UPPERCASE
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SIMATIC IT V6.3 SP1 A5E01140770-01
Preface
Symbol/Convention Indicates...
Italics
The names of parameters that must be replaced with a specific name or value. E.g. filename indicates that the name of the file must be specified; input indicates that the corresponding value must be specified.
>
A succession of commands in which the command preceding the symbol must be selected before the command following it.
SIMATIC IT Training Center

Siemens A&D AS MES offers a number of training courses to familiarize you with the SIMATIC IT product suite. To successfully achieve this goal, training consists of lessons in both theory and practice. Courses are held year-round, according to a program that is published well in advance of the first scheduled session. The material on the basis of which our courses are conducted reflects the result of years of experience in process, LIMS, quality control and production management. All courses are held by expert personnel that are aware of the developments and innovations in the Siemens A&D AS MES product suite. Courses are held in English at the Siemens A&D AS MES Training Centers. Upon request, training courses can also be organized on the customers premises. For more information on the training course calendar, please visit our technical web site (http://www.siemens.com/simatic-it/training).
SIMATIC IT Service & Support

A comprehensive Software Maintenance program is available with SIMATIC IT products. Software Maintenance includes the following services: Software Update Service (SUS): automatic distribution of upgrades and service packs Technical Support Service (TSS): support on technical problems with SIMATIC IT software (standard support and other optional services) Online Support: a technical web site, providing information such as Frequently Asked Questions and technical documentation on SIMATIC IT products
Software Update Service (SUS)

This service provides automatic shipment of new versions and service packs when released. When a new version / service pack is available for shipping, it is typically shipped within one month. One copy of the installation DVD is shipped for each Server covered by Software Maintenance.
Preface Hot fixes (officially tested and released) are not shipped and must be downloaded from the Technical Support Service Web site.
Technical Support Service (TSS)

Siemens provides a dedicated technical support team for SIMATIC IT products.
The following options are available: Standard support: 9 hours/day, 5 days/week Premium support: 24 hours/day, 5 days/week Advanced support: 24 hours/day, 7 days/week
The principal language of the SIMATIC IT hotline is English. SIMATIC IT partners and customers covered by the Software Maintenance program are entitled to direct access to the TSS.
Access to the TSS

To be able to access the TSS, the customer needs to register as a user on the Technical Support Web site. Connect to http://www.siemens.com/mes-simaticit/ and follow the Technical Support Service link. The registration form must be completed with: Personal data The required company and plant information The Contract Number provided by Siemens Back Office when the contract is agreed.
Online Support
A customer who is a registered TSS user, can access the Technical Support Web site (http://www.siemens.com/mes-simaticit/tss), which contains technical information such as: Service conditions (Phone numbers, Working hours, Reaction times,) SIMATIC IT knowledge base: a technical support database that includes practical service solutions from the Technical Support or the SIMATIC IT community SIMATIC IT software (e.g. hot fixes, software examples) and release notes that can be downloaded SIMATIC IT cross-industry libraries that can be downloaded (limited access to SIMATIC IT certified partners) SIMATIC IT product documentation that can be downloaded Frequently Asked Questions and useful tips.
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Table of Contents
1 Overview...............................................................................................................................1-1 1.1 General Architecture...................................................................................................... 1-1 1.1.1 Manufacturing Execution System .....................................................................1-1 1.1.2 A 3-Tiered Distributed System ..........................................................................1-2 1.1.3 Layered Service System ...................................................................................1-3 1.2 Main Functionality .......................................................................................................... 1-4 1.2.1 SIMATIC IT .......................................................................................................1-4 1.2.2 SIMATIC IT Components..................................................................................1-5 1.2.3 SIMATIC IT Historian ........................................................................................1-6 2 Production Information Management................................................................................ 2-1 2.1 Introduction .................................................................................................................... 2-1 2.1.1 Generic Activity Model ......................................................................................2-1 2.2 Defining Operations Capability (Production Resource Management)........................... 2-2 2.2.1 Equipment Resource Information Management ...............................................2-3 2.2.2 Material Resource Information Management....................................................2-4 2.3 Defining Operations (Product Definition Management) ................................................. 2-5 2.3.1 Primary Tasks ...................................................................................................2-5 2.3.2 Collaborative Manufacturing .............................................................................2-6 2.3.3 Interfaces to Product Definition Management...................................................2-7 2.4 Defining Operations Request (Detailed Scheduling and Dispatching) .......................... 2-7 2.4.1 Production Dispatching .....................................................................................2-7 2.5 Production Execution Management............................................................................. 2-10 2.5.1 Primary Tasks .................................................................................................2-10 2.5.2 Collaborative Manufacturing (Integration Strategies) .....................................2-11 2.6 Operations Response (Tracking, Data Collection, Analysis)....................................... 2-13 2.6.1 Primary Tasks .................................................................................................2-13 2.6.2 Collaborative Manufacturing ...........................................................................2-14 3 SIMATIC IT Production Modeler......................................................................................... 3-1 3.1 Software Architecture .................................................................................................... 3-1 3.2 Project Management...................................................................................................... 3-2 3.2.1 System files.......................................................................................................3-2 3.2.2 Project files........................................................................................................3-2 3.2.3 Version Files .....................................................................................................3-3 3.3 Production Modeler Environment .................................................................................. 3-3 3.3.1 External Connections Environment ..................................................................3-3 3.3.2 Libraries Environment .......................................................................................3-4 3.3.3 Plants Environment...........................................................................................3-4 3.3.4 Runtime Environment .......................................................................................3-4 3.4 Basic Concepts .............................................................................................................. 3-4 3.4.1 Equipment Hierarchy Model..............................................................................3-5 3.4.2 Process Segment Model...................................................................................3-5 3.4.3 Logical Classes.................................................................................................3-6 3.4.4 Class Members .................................................................................................3-6 3.4.5 Equipment Rules...............................................................................................3-6 3.4.6 Plant ..................................................................................................................3-7 3.4.7 Master and Execution Copies ...........................................................................3-7 3.5 Modeling the Enterprise................................................................................................. 3-7 3.5.1 Creating the Plant Library .................................................................................3-7 3.5.2 Versioning of User Industry Libraries................................................................3-8 3.5.3 Life Cycle of User Industry Libraries.................................................................3-8 3.5.4 Adding Sub-Libraries ........................................................................................3-8
1-1
Table of Contents 3.5.5 Protecting Library Rules....................................................................................3-9 3.5.6 Creating a Library Class ...................................................................................3-9 3.5.7 Configuring the Class Template .....................................................................3-10 3.5.8 Populating the Class Contents .......................................................................3-10 3.5.9 Working with Class Members .........................................................................3-11 3.5.10 Synchronizing Library Instances .....................................................................3-12 3.5.11 Working with Process Segment Classes ........................................................3-12 3.6 Engineering the Plant .................................................................................................. 3-15 3.6.1 Instantiating the Plant .....................................................................................3-15 3.6.2 Working with the Plant Equipment..................................................................3-16 3.6.3 Working with Plant Process Segments...........................................................3-16 3.6.4 Versioning of the Plant....................................................................................3-16 3.6.5 Life Cycle of Plants .........................................................................................3-17 3.6.6 Synchronizing Instances .................................................................................3-17 3.7 Operating the Business Flow....................................................................................... 3-17 3.7.1 Setting the Plant Version to Share..................................................................3-17 3.7.2 Enabling/Disabling the Plant ...........................................................................3-18 3.7.3 Pausing/Resuming the Plant...........................................................................3-18 3.7.4 Aligning Data in the Components Database...................................................3-18 3.8 Interacting with Operators............................................................................................ 3-19 4 SIMATIC IT Product Definition Manager ........................................................................... 4-1 4.1 Software Architecture .................................................................................................... 4-1 4.2 Basic Concepts .............................................................................................................. 4-1 4.2.1 Product Production Rules .................................................................................4-2 4.2.2 Product Segments ............................................................................................4-2 4.2.3 Product Segment Resources ............................................................................4-2 4.3 Engineering Activities .................................................................................................... 4-2 4.3.1 Creating Product Production Rules ..................................................................4-2 4.3.2 PPR Life Cycles ................................................................................................4-4 4.3.3 Versioning of a PPR..........................................................................................4-5 4.3.4 Creating Standard Product Segments ..............................................................4-5 4.3.5 Health Checking................................................................................................4-6 4.4 Using PDefM Display..................................................................................................... 4-6 4.5 Using GSI SIT Methods ................................................................................................. 4-7 4.6 Importing Data from via B2MML .................................................................................... 4-7 5 SIMATIC IT Material Manager ............................................................................................. 5-1 5.1 Software Architecture .................................................................................................... 5-1 5.2 Basic Concepts .............................................................................................................. 5-1 5.2.1 Material Model ..................................................................................................5-1 5.2.2 Bill of Material ...................................................................................................5-2 5.2.3 Location.............................................................................................................5-2 5.2.4 Handling Units...................................................................................................5-2 5.2.5 Properties..........................................................................................................5-2 5.3 Engineering Activities .................................................................................................... 5-3 5.3.1 Defining the Material Model ..............................................................................5-3 5.3.2 Versioning of Material Definitions .....................................................................5-3 5.3.3 Handling Material Definition Status...................................................................5-4 5.3.4 Defining Material Hierarchies............................................................................5-4 5.3.5 Handling Bill of Materials ..................................................................................5-4 5.3.6 Handling Bill of Material Items ..........................................................................5-5 5.3.7 Handling Hut Types ..........................................................................................5-5 5.3.8 Defining Locations ............................................................................................5-6 5.3.9 Handling Properties ..........................................................................................5-6 5.4 Runtime Operations....................................................................................................... 5-7 5.4.1 Handling Lots ....................................................................................................5-7 5.4.2 Handling Lot Status...........................................................................................5-7 5.4.3 Consuming/Supplying Lot Quantity ..................................................................5-8 5.4.4 Working with Genealogy ...................................................................................5-8
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Table of Contents 5.4.5 Creating Handling Units ..................................................................................5-13 5.4.6 Charging/Discharging Huts .............................................................................5-13 5.4.7 Working with Hut Status..................................................................................5-14 5.4.8 Moving Operation............................................................................................5-14 5.4.9 Handling Property Values of Lots and Huts....................................................5-15 5.4.10 Reading the Lot History ..................................................................................5-15 5.4.11 Working with Sublots ......................................................................................5-15 Using MM Display........................................................................................................ 5-15 Using MM GSI SIT Methods ........................................................................................ 5-15 Importing Bulk Data through Fast Data Import ............................................................ 5-15 5.7.1 Importing Data from External Systems via B2MML ........................................5-16 Extending Material Manager with Custom Objects...................................................... 5-17
5.5 5.6 5.7 5.8
6 SIMATIC IT Production Order Manager............................................................................. 6-1 6.1 Software Architecture .................................................................................................... 6-1 6.2 Basic Concepts .............................................................................................................. 6-1 6.2.1 Order Hierarchy Model......................................................................................6-1 6.2.2 Time Frames .....................................................................................................6-2 6.2.3 Families and Types...........................................................................................6-2 6.2.4 Life Cycles.........................................................................................................6-2 6.2.5 Custom Properties ............................................................................................6-3 6.3 Engineering Activities .................................................................................................... 6-3 6.3.1 Creating Time Frames ......................................................................................6-3 6.3.2 Creating Families and Types ............................................................................6-4 6.3.3 Defining Custom Life Cycles.............................................................................6-4 6.3.4 Creating Custom Properties..............................................................................6-5 6.3.5 Creating Orders from PPR................................................................................6-6 6.4 Runtime Operations....................................................................................................... 6-8 6.4.1 Modifying Order/Entry Quantity ........................................................................6-8 6.4.2 Splitting Entries .................................................................................................6-9 6.4.3 Accessing Runtime Values ...............................................................................6-9 6.4.4 Handling Status Change ...................................................................................6-9 6.4.5 Archiving Data...................................................................................................6-9 6.5 Using the POM Display................................................................................................ 6-10 6.6 Using POM GSI SIT Methods...................................................................................... 6-10 6.7 Managing Operations through the Campaign Tree and Private Xml........................... 6-10 6.8 Importing Data from External Systems via B2MML..................................................... 6-11 6.9 Extending Orders and Entries with Custom Objects ................................................... 6-11 7 SIMATIC IT Personnel Manager ......................................................................................... 7-1 7.1 Personnel Management................................................................................................. 7-1 7.2 Feature Highlight ........................................................................................................... 7-1 8 SIMATIC IT Shift Calendar .................................................................................................. 8-1 8.1 Overview ........................................................................................................................ 8-1 9 SIMATIC IT Data Integration Service ................................................................................. 9-1 9.1 Overview ........................................................................................................................ 9-1 9.2 Software Architecture .................................................................................................... 9-1 9.3 Connector Support......................................................................................................... 9-2 10 SIMATIC IT Client Application Builder ............................................................................ 10-1 10.1 Software Architecture .................................................................................................. 10-1 10.1.1 CAB Environments..........................................................................................10-1 10.1.2 CAB Data Access Strategies ..........................................................................10-1 10.1.3 Basic Runtime Architecture.............................................................................10-1 10.1.4 CAB Portal ......................................................................................................10-2 10.2 Developing CAB Web Pages....................................................................................... 10-3 10.2.1 Data Access....................................................................................................10-3 10.2.2 Business Logic Execution ...............................................................................10-3
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Table of Contents 10.2.3 Security ...........................................................................................................10-4 11 SIMATIC IT Historian ......................................................................................................... 11-1 11.1 Overview ...................................................................................................................... 11-1 11.2 Plant Performance Analyzer ........................................................................................ 11-1 11.3 Historian Data Display (HDD) ...................................................................................... 11-2
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Overview
1.1
General Architecture
The SIMATIC IT architecture has been defined according to some of the most commonly used architectural patterns regarding layered and tiered systems, where: A layer shall be defined as the logical structuring mechanism for the elements that make up the software solution; it deals with the logical structuring of the software application into layers A tier shall be defined as the physical structuring mechanism for the system infrastructure; it explores the physical distribution of the system modules into tiers Furthermore, SIMATIC IT is thought to cover the Manufacturing Execution System (MES) functional requirements as defined by the ISA S95 standard. This means that the criteria in implementing the primary software activities is driven by the functions defined by ISA S95 about Level 3 activity management involved in manufacturing. From this point of view, SIMATIC IT presents also a functional structuring mechanism for the various server applications that make up the software solution. The following sections try to give an overview of these architectures which describe SIMATIC IT including also an overview on how all Production Suite components collaborate together.
1.1.1
Manufacturing Execution System

SIMATIC IT as Manufacturing Execution System (SIMATIC IT MES) is built according to Level 3 ISA S95 standard, which defines the activities of work flow to produce the desired end products. SIMATIC IT MES supplies these activities by means of software components cooperating in a flexible solution in accordance with the customer functional requirements. The general categories of information which can be exchanged through SIMATIC IT MES over manufacturing facility between Level 4 and Level 3 activities are: Production Definition Information Production Capability Information Production Schedule Information Production Performance Information
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Overview General Architecture
As shown in the picture above, even if the definition and the interface with Control Level is out of the ISA S95 scope, SIMATIC IT, being part of the Totally Integration Automation (TIA) strategy, meets the automation requirements of interface between Management (MES) and Control Level. The information flows between the Level 3 and dependent Level 2 is supplied by the execution management activity which includes selecting, starting and moving those units of work (for example lots, sublots, or batches) through the appropriate sequence of operations to physically produce the product. The actual work (manual or automatic) is part of the Level 2,1,0 functions.
1.1.2
A 3-Tiered Distributed System

Tiered Distribution organizes the system infrastructure into a set of physical tiers to provide specific server environments optimized for specific operational requirements and system resource usage. A single-tiered infrastructure is not very flexible; multiple tiers, on the other hand, enable multiple environments. The user can optimize each environment for a specific set of operational requirements and system resource usage. He can then deploy components onto the tier that most closely matches their resource needs and enables them to best meet their operational requirements. Three-Tiered Distribution refines Tiered Distribution to provide specific guidance on structuring the system. The pattern suggests that the system be organized into three tiers: client, business and data. The client and data tiers are selfexplanatory, while the business tier hosts application business components as well as the Web application logic. The internal architecture of SIMATIC IT is physically aligned with the classical three tiers model that is shown in the following picture:
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Overview General Architecture
As from the diagram: Presentation (or Client) tier; it provides the application's user interface (UI). Typically, this involves the use of standard Windows applications and/or ASP.NET technologies for browser-based interaction. Business (or Application) tier; it implements the business functionality of the system. It includes a number of components that provide the ISA S95 specific functionalities and Production Modeler for coordinating their activities. Data tier; applications must access data stored in various repositories, which are most often relational databases. Data access components in this data tier are responsible for exposing the data stored in these databases to the business tier.
1.1.3
Layered Service System

SIMATIC IT is organized into a set of logical layers with the purpose of managing common functionalities into services and specific functionalities into pluggable components. Components can be plugged into and out of an execution environment that exposes an agreed-on set of interfaces through the Service layer. Layered Services Systems work well in scenarios where common functionalities can be identified and implemented into separate software packages (i.e. the Services). These packages provide the available functionalities to the outside world through a set of well-defined interfaces and hide the implementation details from the consuming applications. Note A Software Service is a discrete unit of software which exposes an interface that is suitable for being accessed by other applications. Each Software Service has an associated Interface that it presents to the consumers. Interface provides an entry point that consumers use to access the functionality exposed by the application. The Interface is usually network addressable, meaning that it is capable of being accessed by the consumer over some sort of communication network SIMATIC IT is logically structured into a set of services (SIMATIC IT Services) that are the providers of the common functionalities and a set of modules (SIMATIC IT Components and Production Modeler) that represent the consumers of these functionalities.
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Overview Main Functionality The available Services in SIMATIC IT are logically grouped in the following categories: Communication Services Security Services Compliance Services Diagnostic Service Object Service These services are logically distributed on three different layers (refer to following picture). General-purpose Services are in the lower layer, while MES specific functionalities are provided by Services in the upper layers. The main functionalities offered by each Service are listed in the following paragraphs.
Communication Services
RIS (Redundant Interprocess communication Server): manages TCP/IP based interprocess communications on redundant network (i.e. by using two standard network adapters). NCSERV (Network Configuration Server): manages and shares the network configurations information among all SIMATIC IT modules IPC (Inter Process Communication): used to establish and manage client/server communications DS (Discovery Service): used by client applications in order to get the location of server modules
Security Services
RAC (Remote Access Control Server): manages and shares the user and access rights info among all SIMATIC IT modules UM (User Management): this service manages SIMATIC IT users (e.g. defining, modifying, deleting users groups and scenarios, or policy account settings) AC (Access Control): service used by consumer applications in order to check user rights against requested actions
Compliance Services
AT (Audit Trail): this service is used in order to create Audit Trail records and store them in a secure repository ES (Electronic Signature): service used by consumer applications in order to manage the approval of actions performed on the MES system.
1.2
1.2.1
Main Functionality
SIMATIC IT
SIMATIC IT functionality is provided by means of the following software:
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Overview Main Functionality SIMATIC IT Production Modeler (PM): is a modeling environment in which the functions, belonging to different SIMATIC IT Components, are combined graphically in order to explicitly define the business execution logic of the SIMATIC IT application. SIMATIC IT components: provide basic functionalities according to the S95 standard. Each component addresses specific manufacturing issues (e.g.: Order Management, Material Management, Personnel Management, Report Management, etc.). SIMATIC IT Historian: is a dedicated component to manage historical data. SIMATIC IT Report Manager: is a general purpose reporting tool that can be installed as a product option with SIMATIC IT Historian, Framework and Components. It is also able to integrate with other software products of the SIEMENS family as UNILAB and INTERSPEC.
1.2.2
SIMATIC IT Components
Here follows the list of SIMATIC IT components: SIMATIC IT Business Process Modeler (BPM) is an application server providing methods used by the system to maintain the alignment between the Production Modeler equipment data and the SIMATIC IT components database equipment data. Actually, it allows sharing equipment resource information with the other components. SIMATIC IT Material Manager (MM) is an S95 compliant MES component which manages material resource information on the SIMATIC IT components database. SIMATIC IT Personnel Manager (PRM) is an S95 compliant MES component which manages human resources on the SIMATIC IT components database. SIMATIC IT Product Definition Manager (PDefM) is an S95 compliant MES component which manages product definition information. SIMATIC IT Production Order Manager (POM) is an S95 compliant MES component which manages production-related orders on the SIMATIC IT components database. SIMATIC IT Shift Calendar Manager (SHC) gives the ability to share among other components (e.g.: PRM, PDS-I, OEE product option and so on) common definitions of calendars and work shifts for the management of resources. SIMATIC IT Client Application Builder (CAB) is a platform to develop graphical user interfaces focused on displaying MES specific data. SIMATIC IT Data Integration Service (DIS) is a service that enables XML based data exchange with external systems. SIMATIC IT Predictive Detailed Scheduler-Interactive (PDS-I) is the product option of SIMATIC IT Production Suite. It represents the S95 compliant MES components which manages detailed production scheduling information. SIMATIC IT Production Operation Recorder (POPR) is responsible for tracing on SIMATIC IT components database each production step executed by production Modeler. Usage of this module is deprecated: it is linked with the old PO=Production Operation concept and is kept only for backward compatibility.
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Overview Main Functionality
1.2.3
SIMATIC IT Historian
SIMATIC IT Historian consists of: SIMATIC IT Plant Performance Analyzer (PPA) is capable to perform historical data collection, processing and management. SIMATIC IT Long Term Archiving (LTA) gives the capability to maintain a long history of all data collected and processed by PPA. SIMATIC IT Historian Data Display (HDD) is the sub-component for historical data visualization. SIMATIC IT Process Data Archive (PDA) is able to collect raw process data provided by the RTDS service and archive them in proprietary data storage accordingly to configurable data compression policies. SIMATIC IT Overall equipment effectiveness and Down time manager (OEE/DTM) is the product option of SIMATIC IT Historian for the standard computation of equipment efficiency reports. SIMATIC IT Statistical Process control (SPC) is the product option of SIMATIC IT Historian for the acquisition of process-quality relevant data and the computation of standard-based statistical calculation
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Production Information Management
2.1
Introduction
The following sections try to summarize how production information flows in the SIMATIC IT Production Suite during the development of a MES solution. SIMATIC IT Production Modeler and Components works strictly together in order to fulfill the MES functional requirements as defined in the ISA95 standard. The way production information is managed throughout SIMATIC IT can be represented by the generic activity model of manufacturing operations management defined in the ISA95 standard.
2.1.1
Generic Activity Model

This generic activity model and all the detailed models which will be presented in the further sections are intended to represent the way of a manufacturing information system is defined in SIMATIC IT. The purpose of these models is to identify the data flows within manufacturing operations throughout SIMATIC IT.
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Production Information Management Defining Operations Capability (Production Resource Management) The ovals in the model indicate collections of tasks, identified as the main activities and normally accomplished by the interaction of the totality of the Production Suite components. Lines with arrowheads indicate a set of important information flows between the activities. As from the ISA 95 standard, the collections of tasks involved in MES are summarized as follows: Production resource management can be defined as the collection of activities that manage the information about resources required by production operations Product definition management can be defined as the collection of activities that manage all of the Level 3 information about the product required for manufacturing, including the product production rules. Detailed production scheduling shall be defined as the collection of activities that take the production schedule and determine the optimal use of local resources to meet the production schedule requirements. Production dispatching shall be defined as the collection of activities that manage the flow of production by dispatching production to equipment and personnel. Production execution management shall be defined as the collection of activities that direct the performance of work, as specified by the contents of the production dispatch list elements. Production data collection shall be defined as the collection of activities that gather, compile and manage production data for specific work processes or specific production requests.
2.2
Defining Operations Capability (Production Resource Management)

In SIMATIC IT, there is a dedicated component for each of the activity involved in the management of the information about the production resource. These are: Production Modeler and Business Process Modeler, as to equipment resource information management Material Manager, as to material resource information management Personnel Manager, as to personnel resource information management These components make possible the store of production resource information. Since the information is stored in the SIMATIC IT components database, it becomes available to all the other components of the Suite which can know in any moment everything about the resources of the plant.
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Production Information Management Defining Operations Capability (Production Resource Management)
Also the Business Level is allowed to access this information in order to analyse the production capability, which indicate what is currently available for use. The relation with the Business Level is bidirectional as the data can come also from the business systems through the provided production resource interfaces. As to this, each component has its own method of communication which makes possible the integration of information within the entire Suite environment.
2.2.1
Equipment Resource Information Management
Primary Tasks
As to equipment resource, SIMATIC IT Production Modeler (PM) is the main component involved in the equipment information management as it fulfills to the following tasks: Definition of the Equipment Hierarchy Model (as defined by ISA95) Definition of the Process Segment Model (as defined by ISA95, except for Personnel Resources)
Collaborative Manufacturing
Being based on a multi-platform solution, PM deals with proprietary KB data which must be provided in a format recognizable to the other components of the Suite. This is the main reason why PM relies on BPM: 1. Through PM, the equipment and process segment models are defined. 2. Then, through BPM data is made visible to the other SIMATIC IT components. Data is stored in the BPM repository which shall be defined as the collection of
SIMATIC IT V6.3 SP1 A5E01140770-01 2-3
Production Information Management Defining Operations Capability (Production Resource Management) tables dedicated to the plant data inside the SIMATIC IT components database.
Interfaces to Equipment Management

The equipment hierarchy and process segment models are defined in the PM environment. Apart the modeling activity performed by means of the PM graphical environment, it is possible also to populate a predefined model through XML data files coded according to a proprietary schema definition (i.e. Equipment-Objects.xsd).
2.2.2
Material Resource Information Management
Primary Tasks
As to material resource, SIMATIC IT Material Manager is the component of the Suite dedicated the implementation of the material model and to the management of the material information. Briefly, the primary tasks performable by MM are: Definition of the material model, also with data coming directly from the Business Level Tracing of past, current and future material availability Tracing of material genealogy, performable during the execution phase of the dispatched work directly by the execution management system Exposure of data to Business Level systems
Being founded on a client-server architecture MM provides a set of functions (objects, methods, events and properties) able to perform the tasks related to the material resource management and store data in a specific repository dedicated to the material information. The following diagram, shows the basic data flow related to MM activities:
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Production Information Management Defining Operations (Product Definition Management) As from the diagram: MM main task is to store material information in the MM repository. The MM repository can be defined as the collection of data tables inside the SIMATIC IT Components generic database dedicated to the storage of the material information. MM is able to use information about the equipment hierarchy model stored in the BPM repository in order to import the entire objects hierarchy, or a part of it, as common locations. Locations can be used inside MM to make symbolic associations of lots and handling units to pieces of equipment.
Interfaces to Material Management

The way material information is processed and stored in the MM repository depends strictly on the context in which the SIMATIC IT solution is developed. MM provides various interfaces to the material activities management. The possible approaches are: Use of MM Display Use of GSI SIT methods Import of B2MML data through GSI B2MML methods Import of bulk data through GSI SIT Fast Data Import
2.3
2.3.1
Defining Operations (Product Definition Management)

Primary Tasks
Within the Suite, SIMATIC IT Product Definition Manager is the component dedicated to the management of the product definition information. Through PDefM collection of activities about product definition are made possible including the engineering of Product Production Rules and Product Segments. Its primary tasks are: Definition of the Product Production Rules and Product Segment models, according to the standard provided by the ISA 95, also by importing information directly from Business Level systems Definition of product data according to information provided in the production resource system Check data consistency among the product definition and the currently available production resources Exposure of product definitions to Business Level Systems Exposure of product definitions to dispatching Systems
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Production Information Management Defining Operations (Product Definition Management)
2.3.2
PDefM is founded on a client-server architecture where the provided functionality is exposed by means of a set of functions able to perform the tasks related to the product definition management and store data in a specific repository dedicated to the product definition information:
As from the diagram, PDefM is able to: Manage product definition information through a dedicated repository. .The PDefM repository shall be defined as the collection of specific tables
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Production Information Management Defining Operations Request (Detailed Scheduling and Dispatching) dedicated to the storage of product definition data placed inside the SIMATIC IT components database. Check data consistency between the resources indicated in the product definition data and the equipment, materials and personnel data stored in the repositories of BPM, MM and PRM. Checking is made possible by executing a specific operation named health check.
2.3.3
Interfaces to Product Definition Management

The way product definition data is processed and stored in the PDefM repository depends strictly on the context in which the SIMATIC IT solution is developed. PDefM provides various interfaces to the product definition activities management. According to the way by which functionality is provided: PDefM Display GSI SIT Methods According to the way by which data is processed: Proprietary XML B2MML Standard SIT Proprietary Structures
2.4
Defining Operations Request (Detailed Scheduling and Dispatching)

Production Dispatching
2.4.1
Primary Tasks
Production dispatching in the Suite is accomplished by SIMATIC IT Production Order Manager.
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Production Information Management Defining Operations Request (Detailed Scheduling and Dispatching)
POM primary tasks are: Management of work orders and dispatch lists Creation of orders assigning local resources to production as defined by product definition information Check the production resource availability Modify dispatch lists according to the production resource availability. Dispatch production to start in production lines defined in the execution system Interface dispatching to detailed scheduling systems, where detailed scheduling may come directly from the Business Level systems Note Detailed scheduling information management is provided by the product option Predictive Detailed Scheduler Interactive (PDS-I). PDS-I supplies detailed scheduling requirements by arranging orders and entries of the POM in a production schedule with associated estimated start, stop dates and resource usage. These resources must satisfy a given set of scheduling constraints (precedence and dependencies, capacity constraints, custom defined constraints). Such functionality is provided only by an interactive Gantt-chart supported by automatic constraint verification logic.
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Production Information Management Defining Operations Request (Detailed Scheduling and Dispatching)
POM is founded on a client-server architecture where the provided functionality is exposed by means of a set of functions (objects, methods, events and properties) able to perform the tasks related to production dispatching and store data in a specific repository dedicated to the work orders information:
As from the diagram, POM: Manages a dedicated repository about production request information. The POM repository shall be defined as the collection of tables dedicated orders data placed inside the SIMATIC IT components database Is able to create work orders from PPRs available in the PDefM Check the availability about equipment and materials from the production resource Define and schedule dispatch lists to start in process segments defined in PM
Interfaces to Production Dispatching

The way product definition information is processed and stored in the PDefM repository depends strictly on the context in which the SIMATIC IT solution is developed. POM provides various interfaces to the production orders management. The possible approaches are: Use of POM Display Use of Proprietary XML Use of GSI SIT Methods Import/Export of B2MML data through B2MML GSI Methods
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Production Information Management Production Execution Management
2.5
2.5.1
Production Execution Management

Primary Tasks
The production execution phase is managed by SIMATIC IT Production Modeler, which offers apart of a plant modeling environment, also a runtime environment where plant activities are executed.
As to execution management, PM primary tasks are: Implement custom business logic Start of Process Segments according to dispatch list coming from the dispatching system Parallel execution of the plant activities defined in the various pieces of the equipment as coordinated by the Process Segments or other external agents Performing the various plant execution works in separated execution copies Direction of the performance work with initialization of Control Level activities. Correct use of the resources during the production execution Ensure that the resource are valid for the assigned tasks Exchange information with production resource systems Provide production information and events on production execution management, such as timing, yields, labor and material used, start of runs, and completion of runs.
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2.5.2
Collaborative Manufacturing (Integration Strategies)

The way manufacturing activities are integrated together depends strictly on the context in which the SIMATIC IT solution is developed and by the requirements of the application. Generally, the use cases about integration are summarized as follows: Business Level Integration, where the management level information is critical to business activities and vice-versa; Management Level Integration, where components of the Suite are integrated each other to fulfill and manage production operations Control Level Integration
Business Level Integration

One of the most important requirements for a MES solution is the integration with Business Level, which gathers business planning and logistics information. Managing the exchange of information with business system activities at the level of detail required by the business operations may be required by: Product resource management Product definition management Dispatching management This is the typical use case where the use of SIMATIC IT Data Integration Service (DIS) is required. The main purpose of DIS is to enable a two-way communication between the MES (Manufacturing Execution System) and the business layers, where PM, in this particular case, is the logical-processing component which makes possible the elaboration of incoming data in order to be used by SIMATIC IT components. The general data exchange scenario is summarized as follows: 1. DIS manages the message coming from the Business Level through a specific communication channel, featured by means of one of the connector provided by DIS (e.g. HTTP, IDoc, File System, etc.). The message is generally structured according to the XML schema definition as used by the application at the Business Level (e.g. B2MML standard, proprietary schemas). DIS handles the messages collection by means of a dedicated repository. 2. PM is notified of new incoming messages through the PM Connector. The role of PM is to transform messages coming from the Business Level application to messages recognizable and usable by SIMATIC IT components. For example, in case of B2MML standard, it might be required to extend the XML message with SIMATIC IT B2MML extensions. This is accomplished by PM which is able to get the original message in input, elaborate it through XML manipulation objects (e.g. XML Support Tools or the Data-Builder). 3. At the end of the manipulation the processed message is sent back to DIS. 4. Once the message is returned to DIS repository, DIS forwards the message to the SIMATIC IT components (e.g., POM, PDefM, MM) through the B2MML connector. 5. Differently, the message can be executed directly from PM by means of the B2MML GSI methods provided the SIMATIC IT Component.
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Management Level Integration

The integration at the Management Level is accomplished by the usage of all components combined together in order to fulfill the SIMATIC IT application requirements. From this point of view SIMATIC IT Production Modeler is the elected component as it: Defines and executes the process segments in order to accomplish the production steps according to the dispatched orders Defines and executes the required actions and functions for the various pieces of equipment Coordinates and synchronizes the functional components in accordance with Business Logic operations (i.e. Process Segments), maintaining data consistency among the various SIMATIC IT components In order to fulfill these tasks, PM is fully integrated with the SIMATIC IT components by means of the GSI interface, by which each component exposes its own set of methods and events to PM. In addition, KPI scheduling to PPA is also performable by means of the COM interface.
Control Level Integration

As to SIMATIC IT, integration with the Control Level means integration with SIMATIC PCS 7. This integration can take place at three different levels: Variable/Message level (Lowest) : PCS 7 ES and OS variable as well as alarms can be accessed at MES level: PCS 7 ES variables can be browsed with SIMATIC Tag Browser and then imported into SIMATIC IT RTDS. PCS 7 OS variables can be browsed with SIMATIC Tag Browser or OPC Browser and imported into SIMATIC IT RTDS. PCS 7 OS variables archived in OS Tag Logging can be directly accessed by SIMATIC IT PPA. PCS 7 Alarms can be accessed from SIMATIC IT PPA directly through the SIMATIC Message Channel.
Phase level (Intermediate): SFC Types Integration enables SIMATIC IT to access control system functions directly through Production Modeler without an intermediate batch layer. This approach is particularly useful for managing continuous and discreet processes and also simple batch processes. This kind of communication is made possible by means of the SFC GSI Interface and the SFC Library. Batch level (Highest): Batch-related events and methods can be transferred from SIMATIC BATCH to SIMATIC IT Production Modeler and Plant Performance Analyzer. Additionally, the SIMATIC BATCH Library allows Production Modeler to call SIMATIC BATCH methods from rules thorugh the Batch GSI Interface. As to Variable/Message level of the integration it is important to note the PM is able to access RTDS variables through the SIMATIC IT Interface (GSI). In PM tags are handled in either of two approaches: Predefining a set of cube variables (i.e class attributes of type CUBEVARIABLE) which do not exist in the RTDS data dictionary, then download them into RTDS and create new tags.
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Production Information Management Operations Response (Tracking, Data Collection, Analysis) Defining a set of cube variables which already exist in the RTDS data dictionary, then link them with the RTDS tags. Directly accessing RTDS tags by means of ad-hoc scripts, using the ScriptCaller object.
2.6
Operations Response (Tracking, Data Collection, Analysis)

Primary Tasks
SIMATIC IT Production Suite offers an unique solution able to supply the activities involved in tracking, data collection, analysis management: SIMATIC IT Historian.
2.6.1
Historian primary tasks are: Perform aggregations and analysis on historical data to provide performance statistics Perform and visualize KPI calculations on the base of KPI schedules coming from the execution system Collect, retrieve and archive information related to the execution of production requests and resource usage Provide collected product quality information for comparison against specifications Provide data monitoring about production execution Monitor and archive WINCC and third-party alarm events
SIMATIC IT V6.3 SP1 A5E01140770-01 2-13
Production Information Management Operations Response (Tracking, Data Collection, Analysis) Provide reports on production data
2.6.2
As to SIMATIC IT Historian, the main component involved in the MES collaborative manufacturing system is SIMATIC IT Plant Performance Analyzer.
As from the diagram, PPA: Manage a dedicated repository for historical data, through a set of online and offline databases. In the diagram, the repository is highlighted in aqua, as is not located in the SIMATIC IT components database as BPM repository is. Can import equipment and KPI data from the BPM repository. Activates KPI calculations based on the schedules coming from PM, tracking product operation data Uses RTDS as real-time data source to sample real time values through data archiving tags Uses PDA as historical data source of compressed raw data
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SIMATIC IT Production Modeler
3.1
Software Architecture
The following diagram shows the simplified architecture of SIMATIC IT Production Modeler (PM):
As from the diagram, PM is composed of: Production Modeler Server which coordinates and synchronizes the functional components in accordance with business logic operations. Data is stored in a proprietary repository by means of KB files (i.e. Knowledge Base). Production Modeler Client which supplies the Libraries, Plants, External Connections and Runtime graphical environments, in order to manage KB data such as project settings, user libraries and plants Production Modeler GSI Interface provides a well performing interface based on the proprietary GSI (Gensym Interface) TCP/IP based communication protocol. Also a COM Server is available in order to supply COM capabilities to PM Server, allowing creating, deleting and managing COM compliant applications. As PM saves the defined models in a proprietary format known as Kb data files (or Knowledge Base), in order to expose this data to other components of the Suite it works strictly together with another component: SIMATIC IT Business Process Modeler (BPM). PM relies on BPM about sharing equipment resource information with the other components. Actually, the BPM component: Establishes the information about the equipment resources which must be shared in the collaborative manufacturing environment of the MES solution Synchronizes equipment data to the PM modeled data according to user conditions
SIMATIC IT V6.3 SP1 A5E01140770-01 3-1
SIMATIC IT Production Modeler Project Management Since a copy of the original model is present in the BPM repository, the communication between PM and BPM is crucial in order to maintain data consistency between the model in the KB repository and the one in the BPM repository.
3.2
Project Management
SIMATIC IT Production Modeler is a modular product. The various modules making up the Production Modeler are organized as follows:
3.2.1
System files
The Production Modeler core and engine files are the actual system files. They are installed by default in folder identified by the value of the %ICUBEPATH% environment variable. The environment variable containing this information is %CUBEMESAD%.
3.2.2
Project files
Production Modeler allows users to manage PM plants data through projects. PM is essentially a multi-project core component where there is one PM server instance running for each project. The user creates and runs PM projects from the SIMATIC IT Management Console. When a PM project is started, PM server is also started up automatically with all required system files. All PM project information, such as plants and libraries data, is stored in a private format known as KB files or Knowledge Base. Normally, a PM project handles the following types of file:
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SIMATIC IT Production Modeler Production Modeler Environment
Name <project-name>.kb
Description Contains information about the user application: system parameters, user settings, plants and libraries. Contains the plants specific information (e.g. Plant Definition, Rules, ProductionOperations, External Links, Rules Execution Area.) Contains definitions for all user-defined objects (i.e. Plant Object Classes).
<plant-name>.pln.kb
<library-name>.lib.kb
These user files are stored in folder C:\UserKbs\USERKBS. In this folder the basic libraries kb files (.lib.kb) that the user needs in order to instantiate plant objects are also installed by default. The environment variable containing this information is %CUBEMESAD-USR%.
3.2.3
Version Files
Production Modeler documents, library and plant versions are stored by default in folder C:\UserKbs\DOC. The environment variable containing this information is %CUBEMESAD-DOC%. Each library or plant folder contains, by default, the following folders:
Directory Bitmaps Documents Versions
Contents All bitmaps specific to the library or plant. All documents specific to the library or plant. Each plant or library version saved in SIMATIC IT.
3.3
Production Modeler Environment

Production Modeler is managed through a graphical interface which is made up of four main environments. The following paragraphs introduce briefly the purpose of each environment.
3.3.1
External Connections Environment

External Connections environment allows configuring the communication interfaces with other SIMATIC IT and third-party components. The configuration is relative always to the current project and it is maintained upon saving the project.
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SIMATIC IT Production Modeler Basic Concepts
Communication with SIMATIC IT Business Process Modeler

Caution BPM System GSI Interface is always in active state and in the case the communication with BPM is not established, a warning dialog box appears every some minutes to remember the user to startup the BPM server. Before proceeding with modeling or engineering the PM plant, be sure communication with BPM is correctly established. BPM server should be configured in order to start up automatically as the user is logged in on the Plant of the SIMATIC IT Management Console. This way, prevents possible misalignment between the PM plants relevant data and the equipment model stored in the BPM repository. Furthermore, once the connection has been established, the activity of BPM is completely transparent to the user. As plants data has been downloaded, each time the user save some kb data, the equipment model can be automatically synchronized upon user confirmation.
3.3.2
Libraries Environment
Libraries environment is the place where the modeling phase of the Plant Library takes place. Here the user is able to manage the Plant Library based on the User Industry Libraries and the other system libraries provided by SIMATIC IT. Basically, the user is able to model the Enterprise (the higher level entity in the Equipment Hierarchy Model) in terms of libraries, classes, methods, events and rules.
3.3.3
Plants Environment
Plants environment is the place where the engineering phase takes place. Here the user instantiates the Production Modeler Plant (PM Plant) based on the Plant Library built during the modeling phase and manages the Equipment Hierarchy Model, deciding which objects compose the Plant Equipment. Plants environment allows also testing Plant Equipment activities by manual activation of rules.
3.3.4
Runtime Environment
Runtime environment is the place where the debugging phase takes place. From this environment the user is able to check the execution flow of elements which are activated directly from the Plants environment or from the external (i.e. from POM). This provides real time feedback on the systems behavior, with monitoring and real-time emergency analysis.
3.4
Basic Concepts
This chapter introduces some fundamental concepts related to Product Modeler.
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SIMATIC IT Production Modeler Basic Concepts
3.4.1
Equipment Hierarchy Model

The Equipment Hierarchy Model as defined by ISA S95 standard contains the information about specific equipment instances and the classes of equipment. The Equipment Hierarchy Model defines the physical assets of the enterprise involved in manufacturing. The enterprise is organized in a hierarchical fashion as described by the following diagram:
Equipment Classes
Equipment Classes allows the user to create the Equipment Hierarchy Model as defined by ISA S95 standard. The Equipment Classes are directly provided by the system library named S95-Industry-Library and they are listed here: Enterprise (E) Site (S) Area (A) Cell (C) Unit (U)
3.4.2
Process Segment Model

The Process Segment Model as defined by ISA S95 standard contains information about the commonly defined process segments of equipment. A process segment is defined as the collection of capabilities needed for a segment of production, independent of any particular product. In particular, Production Modeler allows the definition of automated segment which may only define the material and equipment classes needed.
Process Segment Classes

Process Segment Classes allow the user to create automated process segments as defined by the ISA S95 Standard. The Process Segment Classes are directly provided by the system library named S95-Industry-Library and they are listed here:
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SIMATIC IT Production Modeler Basic Concepts Process-Segment On-Event-Segment
3.4.3
Logical Classes
The Equipment Hierarchy Model can be extended with Logical Classes which can be dedicated to supply logical functions typical of software packages (e.g. scheduling management, reporting or printer functions). The Logical Classes are entered at the unit level and can be grouped to form logical cells. The logical classes are directly provided by the system library S95-Industry-Library and they are listed here: Logical-Cell Logical-Unit Production Modeler provides also two classes derived from the Logical-Unit dedicated to integrated custom applications; they are: GSI-Logical-Unit, provided in the GSI-INDUSTRY-LIBRARY Com-Logical-Unit, provided in the CUBE-COM-INDUSTRY-LIBRARY
3.4.4
Class Members
Each class in Production Modeler can be provided with a set of functionality supplied by: Methods: represent the various functions that the object can perform and which are of relevance to the application. Some examples are, add-material, agitate and empty-material for a mixer, start-heating for a furnace, etc. A method can have parameters describing the input and the output data. Events: correspond to an action that occurs within the object and to which the object must react in some ways, e.g., an error in a distillation-tank, a lack of raw-materials in one cell or, a detected delay discovered in on of the areas. An event can have parameters describing the input and the output data Attributes: correspond to different parameters related to the object, e.g., the maximum volume in a mixer, the current temperature in a furnace, the production-rate of a cell or the current workload in an area.
3.4.5
Equipment Rules
Each class can be provided with a set of Rules, grouped in apposite Rule Containers. A Rule is defined as a network of connected objects which establish the runtime execution logic through a path of intermediate steps. For a class, Rules represent the actions which can be performed by means of the available methods, events and attributes. At runtime, the path drives the execution engine through a series of actions according to the logical architecture of the rule.
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SIMATIC IT Production Modeler Modeling the Enterprise
3.4.6
Plant
The Plant is the actual realization of the Enterprise as it is typically composed of the instances provided by the Equipment, Logical and Process Segment Classes. This means that a Plant contains: The Equipment Hierarchy Model instance (the actual model) The Process Segment instances used in the equipment The actual configuration of the equipment Rules and Attributes
3.4.7
Master and Execution Copies

At runtime, when an element of the plant is activated (e.g: a rule), a related Execution Copy is created in the Runtime environment. This means Production Modeler maintains a copy of each executed element for separate debugging and monitoring purposes, thereby managing parallel executions of rules. The original instance from which the executions are started is named Master Copy and it refers to the instance present in the Plants environment.
3.5
Modeling the Enterprise

The following sections try to summarize a comprehensive overview of all modeling activities typically accomplished in the Libraries environment.
3.5.1
Creating the Plant Library

The user is able to create its own libraries deriving classes from the S95-IndustryLibrary provided by Production Modeler. Such libraries shall be defined as User Industry Libraries as are created directly by the user based on the available classes provided by the system. Among the created user industry libraries the user must elect also a Plant Library, which will represent the library required by the Plant and from which the various equipment will be instantiated.
Common-Tools
An User Industry Library has also the functionality of the objects provided by Common Tools, which allow the user to populate its library with dedicated sets of reusable objects each own performing specific tasks. The Common Tools container of a library is provided with the additional containers for the following types of objects: Custom Data Type and Data Builder Definition, useful to process each kind of data (text, float, structure, sequence) through an X-Path like language. Log File, to configure a set of CSV file objects to be used for logging purposes Custom Function, to define your own functions Life Cycle, to import custom life cycle from SIMATIC IT Production Order Manager.
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3.5.2
Versioning of User Industry Libraries

Development of the various User Libraries is managed through a simple versioning system which allows the user to create as many versions of the library as required. When creating a new library version the user can decide if a major or a minor version of it must be created. The versioning system increments automatically the number of the library version with one unit. For example, the minor version of library 3.0 will be 3.1 and the major version 4.0. In addition, it is possible to apply also a description number of the version which will be appended to the minor version number of the library. This number is not compulsory and can be used for general purposes (e.g. internal builds). Each time a new version is created, its description number can be changed without any particular constraint. Note In a project, library versions can be opened in any time, but only one version at time of the same library can be loaded.
3.5.3
Life Cycle of User Industry Libraries

The life cycle of an Industry Library version is very simple. The following diagram shows the possible transitions:
As from the diagram, a library version which is in Editing status can be modified in any moment. All changes inside the library itself are performable. When switching to the In-Production status, no modifications are allowed and commands are not available anymore. This status is particularly indicated when the library has been developed and it must be distributes to other users or customers. Note If your library is in In-Production status, you must create a new version of the library in order to switch back to the Editing status.
3.5.4
Adding Sub-Libraries
When working with a library, the user may need functionality provided by another library. In this case it is possible to add to the library a specified set of Sublibraries. This practice allows you to: create library classes based on the classes of a sub-library, inheriting all methods, events, properties and rules of the sub-library class override members such as rules, methods and events of the class sub-library use Common Tools objects provided by the sub-library
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SIMATIC IT Production Modeler Modeling the Enterprise For example, a user library must have the GSI-Industry-Library as Sub-Library in order to create GSI logical units. Normally the Plant Library contains various system and user libraries as sublibraries, in order to provide the plant with all required objects.
3.5.5
Protecting Library Rules

For user libraries which are in In-Production status, PM provides a protection mechanism by password which can be applied to the library rule containers. Once a password has been assigned to the library, protection can be applied to some or all rule containers present in the library, and each protected container can be subsequently hidden. A hidden container is password-protected. For emergency or debugging purposes, hidden rules can be temporarily viewed upon request in the Plants, Libraries or Runtime environment by providing the library password. Important Once a rule container is protected, it can not be modified any more. In order to be modified, the container must return visible and, being the library In-Production, a new version of the library must be created.
3.5.6
Creating a Library Class

SIMATIC IT Production Modeler is based on object-oriented methodology. This permits one to define classes and to make instances of a class. The basic classes are provided by the S95-Industry-Library. From these basic classes, it is possible to derive sub-classes in order to refine and specialize the behavior of a class. The sub-classes inherit all the class members (i.e. methods, events, attributes and rules) of their superior classes. Additionally, superior class members can be modified by an override mechanism which help to differentiate the elements modified in the sub-class form those which are left unmodified. In a user library, a class can be created based on: the classes available in the S95-Industry-Library any class in the Sub-Library of the current library
S95-Industry-Library Base Classes

The available classes provided by the S95-Industry-Library are logically grouped in the following categories: Equipment Classes: Enterprise, Site, Area, Cell and Unit. These classes make up the physical assets of the Plant. Logical Classes: Logical-Cell and Logical-Unit. These are classes not directly related to the physical assets, but are important as means to supply logical operations. (E.g. in the yoghurt producing cell, a logical unit can be introduced. The unit contains the software for laboratory tests, production orders, batch processing and so on). Distribution Classes: Site-Link and Area-Link. These classes are used in plants distributed architecture.
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SIMATIC IT Production Modeler Modeling the Enterprise Process Segment Classes: Process-Segment and On-Event-Segment. These classes are the actual production segments as defined by the ISA S95 standard. General Purpose Classes: Material-Production-Operation and Material-NonProduction-Operation.
3.5.7
Configuring the Class Template

Each class created in the user library is provided with its own template. The class template determinates the default configuration of all the basic class properties which will be inherited by all the derived sub-classes and instances (e.g. KPI, custom attributes etc.). The relationship between a class template and an individual class is like the relationship between a class and an individual object. An individual class defines how a group of objects can be constructed, while a class template defines how a group of classes can be generated.
3.5.8
Populating the Class Contents

A class can be populated with instances of other classes by configuring the Contents of the class. The Contents of the class can be configured adding instances of a class which is at a lower level respect to the class container, the hierarchy level being established by the ISA S95 equipment hierarchy model. For example, an Area can contain a Cell or a Unit but not a Site. Once a class instance is in the Contents, the functionality implemented by the related class (e.g. rules, methods, etc.) is visible by the class container and can be invoked. For example, an object in the container class can be configured in order to call another object defined by a class instance in the Contents. This means that the methods and events of a Unit can be made visible for the Cell in which the Unit is contained. The methods and events of the Cell can be made visible for the corresponding Area, and the methods and events of the Area can be made visible for the corresponding Site. This mechanism allows defining the equipment hierarchy model with a bottom-up approach: 1. First the lower level hierarchy elements are defined: the Units. 2. Then Cells are created with the units in the contents. 3. Areas are defined with the Cells in the contents which, in turn, contain the Units. 4. The nesting process continues until the higher level in the hierarchy is reached: the Enterprise. Note During the engineering phase, when classes are instantiated, all the objects in the class contents will be instantiated also.
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3.5.9
Working with Class Members

Class functionality is defined and configured by means of its members: Methods Events Attributes Rules
Methods
As in object-oriented programming, a method refers to a subroutine that is exclusively associated either with a class or with an object. Methods are all the tasks which the class may perform with some dedicated rules. Usually a method consists of: The action to perform (the actions provided by the system or defined by the user) A set of input arguments to customize that action with specific values at runtime And possibly a set of return arguments which gives a response about the action or return some data Once a method is defined it can be invoked from a Rule by means of the MethodCaller step. This step allows reusing methods in the rules which at runtime can invoke the method simultaneously.
Events
The events shall be defined as all the messages (which may come from external or internal processes) to which the class must react with some dedicated rules. Events allow building event-based rules which are triggered automatically upon the event occurrence. Usually an event consists of: The message to wait for (the events provided by the system or defined by the user) A set of return arguments which gives a response about the event or return some data Once an event is defined it can be used from a Rule in two modes: By configuring the rule root to start upon the event detection By means of the Wait-For-Event step; this allows waiting the event occurrence after the execution of some intermediate steps in the rule.
Attributes
Each class can be configured with a set of user attributes which can be used for general purposes. PM provides attributes with various type values such as: Integers (INTEGER)
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SIMATIC IT Production Modeler Modeling the Enterprise Strings (TEXT) Floats (FLOAT) RTDS tags (CUBE-VARIABLE) Lists (SEQUENCE) User attributes have a general visibility within the library. This means that any rule from any class can manipulate these variables.
Rules
Rules implemented by a class take advantage of methods, events, attributes and other system objects exposed by the class, in order to coordinate them to fulfill a specific scope. The methods and events are then used in a Rule as building blocks in order to assemble a more advanced functionality. All rules exposed by a class determinate at runtime all actions which actually can be performed by that class and used in the production. A Rule typically consists of: A Root object, which gets the input arguments and redirects the rule return arguments An intermediate network of steps A set of End-Of-Rules, which terminate the rule execution and pass return arguments value to the Root object
3.5.10
Synchronizing Library Instances

As during the modeling phase, classes and class members are continuously modified, PM provides a synchronizing mechanism in order to propagate the changes made to a class to the instances created from that class. Note Synchronize library instances operation performed on a specific class synchronizes all attributes, content, methods and rules of the related instances defined in the library.
3.5.11
Working with Process Segment Classes

According to the S95 standard a process segment is a logical grouping of personnel resources, equipment resources, and material required to carry out a production step. Again a process segment is defined as the collection of capabilities needed for a segment of production, independent of any particular product. From the Production Modeler point of view, Process Segments are production operations. A production operation is used to implement and coordinate more complex behavior in the PM Plant simply by combining the functionality exposed by the equipment classes and other production operations.
Basic Concepts about Process Segments

Process Segments typically consist of:
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SIMATIC IT Production Modeler Modeling the Enterprise a process object a set of segment resources all the others members available also for the other S95 base classes The process object (the Process-Object template property) determinates the scope of the process segment within the library. In other words, each process segment is related to a specific class for which it wants describe and direct the behavior. Normally, the process object corresponds to the equipment object related to that specific production step. For example, in the manufacturing of the chocolate the production step known as roasting is normally performed on big rotating ovens where cocoa seeds are roasted. From the point of view of your plant, a process segment can be defined for the roasting production step. The process object of this process segment could be any rotating oven Unit defined in your Plant Library. The process segment will make use of that unit functionality in order to accomplish the process of roasting. The segment resources define all the inputs required by the process segment in order to accomplish the production step as defined by the ISA S95 standard in relation with automated process segment (process segments without personnel resource). Segment resources which can be added to a process segments are: I/O Parameters (Input and Return Arguments) Material Specifications (Input and Return Mat Spec) Equipment Specifications (Equipment Spec) In particular from the S95-Industry-Library, two types of process segments are available: Process-Segment, useful in continuous manufacturing operations On-Event-Segment, useful in discrete manufacturing operations
Using the Process-Segment Class

A process segment which is created upon the Process-Segment class consists of: Its process object Its set of segment resources All others members available also for the other S95 base classes A single production rule The production rule (the Rule of Rules) is the function within the process segment which drives the production step toward its completion. Rule of Rules allows defining the production operation graphically, thereby easily modifying the processes in case that the behavior needs to be adjusted. Rule of Rules are based on the same concept as normal rules are. A sequential order of the building blocks is described graphically through a logical execution flow which carries out the production operation. Through Rule of Rules it is definitively described the desired behavior of the equipment such as an Enterprise, a Site, an Area, a Cell or a Unit.
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SIMATIC IT Production Modeler Modeling the Enterprise A production operation, for example, at the Site level, can use in its Rule of Rules the methods and events exposed by the Site process object. If the Site contains some Areas, also the functionalities of the Areas are exposed. Furthermore, a production operation at the Site level can also use production operations defined for the contained Areas (i.e. start other process segments). A production operation at the Site level is referred to as a Site production operation. A Rule of Rules is composed of three primary root objects which are executed in sequence when the process segment is started; they are: Init, for the control of all the initialization procedures Exe, for the control of the execution of the single operations End, for the control of the termination procedures Generally, each of these roots is connected to a logical network of steps which models the business flow of the process, driving the execution flow at runtime. Normally, the used steps may correspond to: A general purposes object provided by PM, such as the Xml-Data-Local-List or the Data-Builder. Script-Caller object, by which it is possible to call specific functions provided by PM. Normally, this step is used to access the segment resources for which ad-hoc functions are provided. Start-Segment object, by which it is possible to call other process segments. Method-Caller and Wait-For-Event objects, by which the exposed methods and events of the process-object can be invoked Pm-Event-Deduction object, by which the process object rules can be activated.
Using On Event Segments

On-Event-Segment class is derived from the Process-Segment class but differs from it as the production process is driven by a set of transition rules (known as Status-Transition Rules) instead of a single production rule. A process segment which is created upon the On-Event-Segment class is characterized by: The process object The life cycle; about this, SIMATIC IT Production Order Manager is the component which defines the life cycle and handles the state machine. PM imports the life cycle from it and generates as many transitions (known as Status-Transition objects) as specified in the life cycle The set of segment resources A single production rule All others members available also for the other S95 base classes Life cycle determinates the possible transitions to which the process segment must react. Once the process segment has been associated to its life cycle it is possible to create and model the transition rules assigning to it the required transitions. The user is able to: Create its own transition rule and associate it to as many transitions as required Let some transitions not associated
3-14 SIMATIC IT V6.3 SP1 A5E01140770-01
SIMATIC IT Production Modeler Engineering the Plant During the configuration phase, PM gives also the possibility to create automatically one transition rule for each transition present in the life cycle. This is the generic configuration where the process segment reacts with a specific rule to each transition. For transition rules only, PM provide a specific object named Refuse-Transition. This object can be used within a transition rule as termination step to roll back a transition. It allows you to terminate the execution of a transition rule, and consequently the execution of the process segment as well, with the particular status 'Refused'.
Starting Process Segments

Process Segments can not be started manually from Production Modeler environment, but only automatically, upon dispatching Production Orders created from Product Production Rules.
3.6
Engineering the Plant

The engineering phase is the phase that links the model developed in the Libraries environment to the actual systems and process plant; this is accomplished mainly in the Plants environment where objects are instantiated from the user library elected as Plant Library. The following paragraphs try to summarize the engineering activities typically performed in the Plants environment. Note that at this stage, you can start testing your business flow step-by-step and further specify it, according to your needs. To accomplish this, you will simulate the activation of the previously configured Rules in order for the working model to be tested and fully implemented.
3.6.1
Instantiating the Plant

Once User Libraries are correctly modeled and loaded in the project, it is possible to create the various PM plants. PM plants actually are instances of the classes available in the Libraries environment of the currently loaded PM project. A PM plant can be created only upon the following S95 base classes: Enterprise Site Area At the moment of the creation, the user chooses the specific class to be instantiated among the user libraries defined in the current project or the S95Industry-Library. If the class being instantiated has been configured with contents, also the contents objects will be instantiated. Important A plant requires always a user library (the Required-Library) in order to be instantiated which is the elected plant library; this library contains all the possible equipment classes which can be instantiated in the Plant itself.
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SIMATIC IT Production Modeler Engineering the Plant
3.6.2
Working with the Plant Equipment

During the engineering phase, new equipment items can be added to the PM plant and the existing ones can be modified as well. The population of the plant equipment is completely left to the user. In any moment new classes can be instantiated, choosing the base class from the S95Industry-Library, or from the plant library. About class members, in the Plants environment the user is able to modify rules and user attributes of the plant equipment instances without modifying the related plant library classes.
3.6.3
Working with Plant Process Segments

Once the PM plant is defined and populated with the equipment items, process segments can be added to the equipment. Adding a process segment to an equipment item determinates automatically the process object of the process segment itself. This implies: Process segments whose process object is not configured (i.e. the process object is left to NULL) can be added to any equipment item. Process segments whose process object is previously configured can be added to any equipment item provided that it is compatible with the process object itself. This means that process segments which have an area as process object can be added to an area but not to a cell or unit. Tip The way the process object must be configured depends strictly on the functionality the process segment must provide. Generally, process segments with generally purposes (e.g. which can be used either by Areas, Cells or Units) should be configured with a null process object. Process segment with specific purposes (i.e. which can be used only by a specific class) should have their own process object set during the creation of the library, in the modeling phase.
3.6.4
Versioning of the Plant

For plants, PM provides the same versioning mechanism which is provided for user libraries. The important thing to note is that a plant has always a required library (i.e. the plant library), but the versions of a plant may not correspond to the version of its library. When a new version of the required library is created in the Libraries environment, PM asks if a new version of the related plant must also be created. The user can choose to: Create a new plant version; in this case the current version is saved and unloaded and a new version is created. Therefore, the unloaded plant version will require the old library version. Do not create a new plant version; in this case the current version is just updated and it requires the new version of the library.
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SIMATIC IT Production Modeler Operating the Business Flow Tip When creating a new version of a plant library, it is suggested to create always a new corresponding plant version. This facilitates the individuation of the required libraries for the plants during the deployment operation.
3.6.5
Life Cycle of Plants

Plants are subjected to the same life cycle of user libraries. The only thing to note is that the change of a Plant from the Editing status to the In-Production status is possible only if the plant library is already changed to the In-Production status.
3.6.6
Synchronizing Instances
During the engineering phase, it is allowed to switch back in the Libraries environment in order to apply some modifications to the libraries. In this case, in order to maintain library data modifications aligned with the plant, PM provides a synchronizing mechanism. Basically, synchronizing applies changes made upon the library classes to the related instances in the plants. If some rules have been modified directly from the Plants environment all changes will be lost reflecting the related library rule structure. Important Synchronization can be performed either in the Libraries or in the Plants environment. When synchronizing in the Libraries environment, all class instances are synchronized with their related class. On the other hand when synchronizing in the Plants environment, only one specific class instance at a time is synchronized with its related class Furthermore, PM provides a check about rules which have been added to the plant equipment directly from the Plants environment. Upon synchronization, even if these rules are not present in the library, they are not deleted to prevent to lose them. However this practice is not suggested and new rules should be added always in the library from the Libraries environment.
3.7
Operating the Business Flow

After the modeling and engineering of the plant, the operating phase can start. At this stage the plant model (i.e. the equipment hierarchy and process segment models) is shared with the Components and the actual production operations can start upon dispatching of production order.
3.7.1
Setting the Plant Version to Share

Plant information stored in the BPM repository is not accessible to the other Components until the user sets as current a specific version of the plants to share. This operation is performed from Plants environment, where the user must select the plant and set as current the version to be shared. Note that, this mechanism provides the components with: only one version of the same plant at a time
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SIMATIC IT Production Modeler Operating the Business Flow and a single version of distinct plants at a time This means that if data of the plant SITE-1 v2.0 is shared, SITE-1 v.1.0 data can not be shared at the same time, as the current plant version is SITE-1 v2.0. In addition to SITE-1 v.2.0 data, there could be shared data about the plants SITE-2 v3.0 and AREA-1 v.1.0.
3.7.2
Enabling/Disabling the Plant

In the case data pertaining to a specific plant version must be hidden to other components for some specific purposes, it is possible to disable a plant. A disabled plant in SIMATIC IT Production Modeler has a grey icon and is no longer visible by components. Data is retained in the SIMATIC IT BPM Server, but plant is unloaded and its rules can no longer be activated as plant data is temporarily not shared.
3.7.3
Pausing/Resuming the Plant

Pause/resume of a plant which is in execution is possible by specific commands available in the Plants environment. The pause of the plant causes all its running rules and process segments to be frozen temporarily without aborting their execution. As consequence, on-the-fly changes can be applied on libraries or plants and successively paused plants can be resumed letting the plant continuing the previously paused activities.
3.7.4
Aligning Data in the Components Database

As it is responsibility of Production Modeler to maintain plant data aligned with BPM data, if the communication with Production Modeler and BPM is active, PM data is continuosly and transparently synchronized inside the BPM repository. However, the database may be not up-to-date for any of the following reasons: When a network problem occurs. When a plant has been updated in a disconnected configuration, i.e. while the BPM server is not running. When a new plant version is created. While downloading single plant/library elements and you choose which data can be shared between components and when. Should any of the above situations arise, the download object operation is available in order to align PM plant model with BPM data. In addition, to speed-up this operation, also the Lite Download option is available in order to download only a subset of data. Generally, about the download object: Can be performed either on the entire plant, in order to download all related data, or on specific equipment items, in order to download/update just specific data The user is able to download as many plants as required and also many different versions of the same plant
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SIMATIC IT Production Modeler Interacting with Operators Note After the plant model has been downloaded, data is automatically updated and synchronized upon save operations performed from the PM Plants and Libraries environment, provided that communication with BPM is correctly maintained.
3.8
Interacting with Operators

SIMATIC IT Messaging Manager (MSM) is a service used in order to dispatch configurable dialog windows (Message Boxes and Dialog Boxes) on local and remote computers and to manage the data entered by the users. MSM consists of: Client library: used by Production Modeler (or external applications) to request the delivery of a Message Box or Dialog Box Messaging Server: handles the delivery of messages and stores event and message data into the SIMATIC IT Messaging Manager historical database. Its parameters can be configured by the user. Configuration client: defines Message Box and Dialog Box templates Runtime client: for Message Box and Dialog Box browsing and display In the Production Modeler environment Rules can be configured with a specific step (i.e. the Send-Message object) in order to ask the Messaging Manager to dispatch a message to an operator. The data entered by the operator can be returned to the calling step.
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SIMATIC IT Product Definition Manager
4.1
The simplified architecture of the PDefM component is outlined in the following diagram:
As from the diagram, PDefM: PDefM Display represents the Presentation Tier PDefM Server (one of the Production Application Servers) represents the Business Logic Tier Components Database represents the Data Tier

PDefM exposes a GSI interface to interact with Production Modeler. In order to process product definition data coming from ERP systems PDefM is able to communicate with DIS through the B2MML connector.
The integration among the Production Application Servers is performed at database level.
4.2
Basic Concepts
This chapter introduces some fundamental concepts related to Product Definition Manager. In particular, the main engineering entities are defined and the logical relationships between them are illustrated as well.
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SIMATIC IT Product Definition Manager Engineering Activities
4.2.1
Product Production Rules

According to the ISA S95 standard, Product Production Rule (PPR) is defined as as the information used to instruct a manufacturing operation on how to produce a product. A Product Production Rule (PPR) defines the steps to perform in order to make up a product (i.e. the final material). It addresses the basic manufacturing question: How the product must be produced?
4.2.2
Product Segments
As defined in the ISA S95 standard, a Product Segment is defined as as the overlap of information between product production rules and the list of all resources required to produce a product. A Product Segment defines the parameters, materials and equipment resources in order to accomplish a specific production step. It addresses the basic manufacturing question: What resources must be used to perform this specific production operation? Product Segment is strictly related to production operations as it normally refers, identifies or corresponds to an available process segment defined in the production resource. Differently of the associated process segments, which are product independent, a Product Segment is related to a specific product.
4.2.3
Product Segment Resources

Each Product Segment brings a set of resources consisting of: Parameters, typically related to process segment parameters, define the names and types of the values that may be sent to the control system to parameterize the product Equipment Specifications, related to process segment equipment specifications Material Specifications, related to process segment material specifications Personnel Specifications, identifying to a personnel capability. Execution Equipment, typically related to the process object of the process segment
4.3
Engineering Activities
The following sections try to summarize the most important engineering activities which can be performed by the Product Definition Manager functionality.
4.3.1
Creating Product Production Rules

The first engineering activity in PDefM is the creation of the Product Production Rule (PPR). PPR can be created either from scratch or by cloning an existing PPR or by creating a new version of an existing PPR.
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SIMATIC IT Product Definition Manager Engineering Activities Each PPR is identified in the system by name and version. PPR can be defined as detailed data structure bringing product definition information: Plant name Final Material Life Cycle Version and Priority Custom Properties Product Segments
Assigning a Plant to the PPR

During the configuration phase a plant must be assigned to the PPR. The plant is the one running the process segments to which the product segments will be related. This allows the definition of distinct PPRs for the various plants defined in the product resource information, and therefore the possibility of executing production orders throughout several area and equipment. The plant must be specified with its name identifier and version. If the PPR will be used for the creation of production orders through POM, the specified plant must be among those versions of plants which are in the BPM repository. If using the PDefM Display you can browse all plants stored in the BPM repository.
Specifying the PPR Final Product

Each PPR defines a final product, which corresponds to the material definition to be produced (i.e. the final material). Final material is assigned to the PPR by specifying: Material definition identifier Material definition version BOM identifier among the alternative BOMs assigned to the material definition version Batch quantity Batch quantity specification includes information about the amount of product defined by the Product Production Rule about the assigned material definition. The Batch Default Size establishes the default quantity of product to be produced as the Minimum and Maximum Sizes define the limit of the product amount which can be produced by the PPR itself. Batch specification is particularly important as it has a direct consequence on the producible quantity of the production orders which can be derived from the PPR. When using MM for managing material resource data, you can specify a final material among those material definitions defined in the MM repository.
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SIMATIC IT Product Definition Manager Engineering Activities
Assigning Additional Information

When using the PPR for the creation of production orders, additional information can be specified to automatically predefine certain values of the order itself: The target order life cycle: this will set a specific life cycle for the orders derived from the PPR. The status of the order will be the one which is defined as Initial in that life cycle. Only life cycles defined in POM can be specified (system and custom life cycles are allowed). BPO (Background Production Operation): this will set a specific Production Operation for the order derived from the PPR. Only production operations stored in the BPM repository can be specified (Material-Production-Operation and Non-Material-Production-Operation subclasses are allowed).
4.3.2
PPR Life Cycles
Life Cycles and Attributes

PDefM provides two basic system life cycles for PPRs: Development (DEV) Standard (STD) Life cycles in PDefM are characterized by two attributes: Active, determining whether or not the PPR is ready to be used for creating production orders through POM. Editable, specifying if the PPR configuration can be modified or deleted.
DEV Life Cycle Statuses

The DEV life cycle is characterized only by the NA status (i.e. Not Assigned). This life cycle it is generally used during the developing and testing phase of the PPR or when the PPR does not require any particular approval condition. A PPR which is in NA status is editable and active at the same time. This means that you can modify the PPR configuration, delete it and also create orders from it through POM. In any time, the PPR can switch to the STD life cycle.
STD Life Cycle Statuses and Transitions

The STD life cycle is composed of the following statuses:
Status Editing (ED) Ready for Approval (RA) Approved (AP) Obsolete (OB) Active False False True False Editable True True False False
As shown in the table each status is characterized by a combination of the two attributes which determines the characteristics of that specific status.
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SIMATIC IT Product Definition Manager Engineering Activities A PPR begins its STD life cycle in the ED status with the objective of reaching the AP status. During the ED and RA status the PPR can be modified, deleted but not used to create production orders. In these statuses, the PPR can also switch to the DEV life cycle if required. Once in the RA status it can change to the AP. When the PPR reaches the AP status it is not allowed any modification on it any more and production orders can be created from it. The status of a PPR cannot be changed to Approved if it contains a product segment reference to a PPR which is not Approved. Once in the AP status the PPR can change to the OB status. A PPR in this status is not editable and not active, and can not be used any more; it is maintained in the database for tracing purposes only. If the status change requires one or more electronic signatures, the status will not be changed until the electronic signatures have been attained.
4.3.3
Versioning of a PPR
PDefM manages PPRs through a simple versioning system which allows creating new PPRs from existing ones. The versioning mechanism is automatic and it is applied on the minor or major version of the PPR. When a PPR is created the first time, the first version of it is defined in the system (i.e. 1.00). Once a new version is created upon an existing one, the system increments automatically the minor or major version numbers of one unit according to the user conditions. For example, based on this first version (e.g: 1.00), a minor version can be created (e.g.: 1.01) or a major version (e.g.: 2.00). Generally, the new version of a PPR: Is based upon an existing version Has a new validity range in terms of time Generally, new versions are created in order to modify the configuration of a PPR which is not more editable (i.e. when it is in the AP or OB status).
4.3.4
Creating Standard Product Segments

Once the first version of a PPR is defined, Product Segments can be created inside it. Such a Product Segment has always associated a process segment which may correspond to one among those present in the BPM repository. A Product Segment is normally composed of the following elements: Input/output Parameters: used to specify process segment and/or custom parameters. When creating a Product Segment related to a Process Segment in PM, the parameters defined in the Process Segment must be specified. If the PPR will be used for the creation of orders through POM, custom parameters will be mapped as order properties. Specifications: used to group the required list of items such as equipment items, materials and personnel group quantity in correspondent equipment, material and personnel specifications.
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SIMATIC IT Product Definition Manager Using PDefM Display When creating a Product Segment related to a Process Segment in PM, each equipment and material specification must be associated to those defined in the Process Segment. In this case, in the equipment specification the list of plant equipment for that particular specification must be indicated. If using MM, in the material specification the list of material definitions used by that particular specification must be indicated.The material definition will be assigned with its priority BOM, if defined, quantity, yield and scrap values. If using PRM, in the personnel specification the list of groups (with the required number of people) must be specified. Execution Equipment: used to list the equipment items which will be used by the assigned Process Segment. When creating a Product Segment related to a Process Segment in PM the equipment items corresponds to the process objects of the Process Segment. In this case, the equipment items should be specified according to the following rules: For not-parametric process segments one single process object should be indicated. For parametric process segments a class equipment or from one to many equipment instances. In this latter case, each equipment instance will have a priority. At the POM side, the Process Segment with higher priority will be used among those momentarily available in PM.
4.3.5
Health Checking
The Health Check operation is an optional operation which can be performed in order to check the consistency between data specified in the PPR and data present in the production resource information (BPM, MM, PDS-I, PRM repositories). Note that the two basic conditions are compulsory for the creation of production orders from a PPR: The PPR is in a status with the active attribute set to true (i.e. AP for STD or NA for DEV) The Health Check have been successfully performed Health check can be successively performed on PPR which are in Approved status, in order to check if data consistency with the other SIMATIC IT components is maintained in the PPR configuration along the time. For example, the Process Segment associated to one of the PPR Product Segment can be no more present in the BPM repository. In this case the Health Check fails signaling the inconsistency.
4.4
Using PDefM Display

PDefM is provided with a user-friendly graphical interface which allows the user to take advantage of the functionality and perform engineering activities as fast as possible.
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SIMATIC IT Product Definition Manager Using GSI SIT Methods In particular, through the PDefM Display the interaction with production resource information as defined in the other components repository (BPM, PRM, MM) is made possible through the use of dedicate Explorer windows. Explorers are able to scan the SIMATIC IT production resource information with advanced queries and filters, minimizing operator input time and errors.
Importing Data via Proprietary XML

PDefM provides a proprietary XML schema definition (PPRPrivate.xsd) by which is possible to import data in PDefM via XML files. By this schema, xml data specifying huge lists of PPR can be imported/exported into/from the PDefM repository directly using the PDefM Display.
4.5
Using GSI SIT Methods

PDefM provides a set of GSI SIT methods in order to perform engineering activities from rules built in the Production Modeler environment. Generally the most important operations are summarized as follows: Import PPR lists for creation of new PPRs or update of existing PPRs Retrieve PPRs Delete a specific PPR Change the PPR status Retrieve Product Segments from a specific PPR Add/Delete Product Segments to/from a specific PPR Perform normal or lighter Health Check
4.6
Importing Data from via B2MML

A set of GSI methods is provided to interface Business Level systems which manage data structured according to the B2MML standard:
Method SIT_AddB2MMLData Purpose Creates or replaces PPRs in the PDefM repository according to a B2MML xml string Creates or replaces PPRs in the PDefM repository according to a SIT structure B2MML-like Returns specific PPRs in a B2MML xml string
SIT_AddB2MMLDataStructure
SIT_GetB2MMLData
In particular, PDefM supports the following schema definitions: B2MML-V02-ProductDefinition.xsd (B2MML v2.0 for product definition) B2MML-V02-ProductDefinition_SITExtension.xsd (proprietary extension of B2MML v2.0 for PDefM)
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SIMATIC IT Material Manager
5.1
The simplified architecture of the MM component is outlined in the following diagram:
As from the diagram, MM is based on a Multi-tier architecture (three-tier) where: MM Display represents the Presentation Tier MM Server (one of the Production Application Servers) represents the Business Logic Tier Components repository represents the Data Tier MM exposes also a GSI interface in order to interact with Production Modeler. The integration among the various Production Application Servers is performed at database level.
5.2
Basic Concepts
This chapter introduces some fundamental concepts related to the engineering and runtime entities which can be managed by Material Manager.
5.2.1
Material Model
The material model defines the actual materials, material definitions, and information about classes of material definitions.
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SIMATIC IT Material Manager Basic Concepts Material Manager allows managing material resources in terms of a hierarchy model as defined by the ISA S95 standard. Additionally, other entities are introduced in order to fit better the user requirements: Material Type identifies a group of Material Classes all related to specific purposes in the production (e.g. raw materials, intermediate materials, subassemblies, parts, and consumables). From a Material Type zero or more Material Classes can be derived. Material Class is directly related to Material Type and it identifies a group of material definitions for use in production scheduling or processing (e.g. water -raw material). From Material Class it is possible to derive zero or more Material Definitions. Material Definition is a specialization derived from a Material Class (e.g. recycled water - raw material). It is a means to describe production goods with similar characteristics which can be used to make a product, but also to represent the product itself. From a Material Definition zero or more Lots can be defined. Material Definition. Material Lot uniquely identifies a specific amount (countable or weighable) of a specific Material Definition (e.g. 2 liters of recycled water - raw material).
5.2.2
Bill of Material
According to the ISA S95 standard, the bill of material is a list of all materials required to produce a product showing the quantity of each required. These may be raw materials, intermediate materials, subassemblies, parts, and consumables. Note that the bill of material includes material product-related but also materials not related to production, such as shipping materials. Bill of Material is always an alternative among a group of Bills of Material. This is because the material requirements to make a product may change and must be handled in a flexible way.
5.2.3
Location
Location is the determination of a storehouse for material lots. Locations can correspond directly to objects defined in the plant model (e.g. sites, areas, etc) or to private places not related to the plant equipment. Location allows the definition of places where materials can be moved into and from.
5.2.4
Handling Units
Handling Unit (HUT) is a means to describe a storage unit where lots can be allocated. HUT allows the definition of containers which can be charged and discharged with specific amounts of material.
5.2.5
Properties
Properties describe physical characteristics which can be associated to materials and handling units. Properties are typically dedicated to measure values according to a specific unit of measure provided by the International System of Units (SI).
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SIMATIC IT Material Manager Engineering Activities Material Manager allows the assignment of properties to logical entities such as material classes, material definitions and handling unit types for modelling purposes. The values properties assume are specified at runtime in the related lot or HUT properties.
5.3
5.3.1
Defining the Material Model
The most important activity in MM is the definition of the material model. When defining the material model the user must create and configure entities according to the logical relationships established by the MM object model. This means that, basically, the material model must contain: 1. One Material Type 2. One Template Material Class based on that specific Material Type. 3. The first version of one Material Definition based on that specific Template Material Class. Since the material model can be as complex as required and the use of the MM entities depends strictly on the requirements of the SIMATIC IT application, the way the model must be defined is application-dependent.
5.3.2
Versioning of Material Definitions

Each Material Definition is versioned through a versioning system which allows the creation of new versions of the same Material Definition, with distinct characteristics but based on the same Material Class. When creating a new Material Definition from an existing Material Class the system automatically generates the first version of the Material Definition where the major version is 1 and the minor version is 0 (1.0). Going through the life cycle of the Material Definition, new versions can be created based on existing versions. In particular, it is possible to create a major version based on any existing previous version of the Material Definition. For example, a possible major version for lecithin 1.0 is 2.0 (but also 3.0 or 4.0 can be created directly from 1.0, and so on). In addition, also minor versions can be managed and increased of one unit at a time. For example, the candidate minor version for lecithin 1.5 is 1.6, but can not be 1.7 or 1.8. Each Material Definition version is identified in the system by: its unique identifier and the related major and minor version integers This means that in the system a Material Definition with same identifier may exist but distinct version. Material Definition with the same identifier but based on a distinct Material Class can not exist.
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SIMATIC IT Material Manager Engineering Activities
5.3.3
Handling Material Definition Status

A version of a Material Definition can pass: From Edit to Test and vice-versa From Test to Ready From Ready to Approved From any status to Obsolete Each status is characterized by a set of attributes which determinate the possible actions the Material Definition can undergo:
Attribute Is Editable Is Deletable Is Approved Is Obsolete Description The version can be modified The version can be deleted The version is approved The version is obsolete
By default, the Edit status is characterized by the Is Editable and Is Deletable attributes set to true. This means that a Material Definition which is in this status can undergo to modifications and can be deleted at any time. This status is particularly indicated for Material Definition versions which in a test phase. When a Material Definition is in Approved status it can not be modified or deleted and lots or sublots can be created from it. This status is typical of Material Definition versions which are ready to become part of the production resource. The only way such a version can be deleted is to switch to the Obsolete status. In addition, among those versions which are in Approved status, MM allows to flag one specific version as Current. This is particularly useful when the user wants elect a specific version as the currently used among the approved. In addition, it is possible to add a set of custom statuses. Each status can be configured only with the attributes provided by the system.
5.3.4
Defining Material Hierarchies

MM allows the definition of special classes, known as Non-Template Material Classes, which permit the creation of material hierarchies. Each Non-Template Class may be father only of Non-Template Classes and, at the same time, it may have other children Non-Template Classes. Once the hierarchy has been defined, Material Definition versions can be associated to one or more Non-Template Classes through a bind operation. Also the disassociation is allowed through an unbind operation. The association of a Material Definition with a Non-Template Class has the general purpose of material classification and data retrieval.
5.3.5
Handling Bill of Materials

After a Material Definition version is created, it is possible to create for it a set of Bill of Materials (BOMs). Each BOM associated to a version of a Material Definition defines an alternative BOM for that version.
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SIMATIC IT Material Manager Engineering Activities BOM alternatives in MM are managed by a simple mechanism of priority assignment. Each time a BOM is created, an integer is automatically assigned to it, defining the BOM priority within the set of existing BOMs. By default, MM assigns the priority 0 (i.e. higher priority) to the first created BOM, and afterwards each new BOM will have a priority increased by one unit. Obviously, the user is able to set in any time the BOM with the higher priority. A BOM is identified in the system by: its unique identifier and the related Material Definition version Each BOM is normally characterized by Its priority integer A quantity, defining the amount of material handled by the BOM related Unit of Measure (which must be compatible with the associated Material Definition version) Validity range in terms of time Properties with default values BOM Items, which determinate the materials required by the BOM itself
5.3.6
Handling Bill of Material Items

After a BOM is created for a specific Material Definition version, the user must define the materials required by the BOM itself. To each BOM item, MM applies a simple mechanism of grouping. Each time a BOM item is created, the user must choose the group identifier to which the item must be assigned and the priority within that group. In these terms, BOM items are those materials chosen as preferred among a set of material groups. The BOM item can be assigned to a BOM are all the available Material Definition versions defined in the Material Model. Normally, each BOM item is characterized by: The quantity, which indicate the amount of required material Related unit of measure (compatible with that of the associated Material Definition) Properties, which are the same of the Material Definition versions, but new properties can be added as well
5.3.7
Handling Hut Types

MM provides the following basic set of Handling Unit Types: Bin which normally may contain Box and Grid Box which normally may contain Pallet Additionally, the user can define its own set of HUT Types. Existing properties with default values can be associated to Hut Types.
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SIMATIC IT Material Manager Engineering Activities Once Hut Types are defined they are identified in the system by a unique identifier by which the various Hut instances can be created at runtime.
5.3.8
Defining Locations
MM allows the definition and usage of locations as storage places for handling units and lots. Locations can be defined by: Importing Common Locations, which permits to import specific equipment actually stored in the BPM repository. Creating Private Locations. The available location types correspond to the basic equipment types specified in the ISA95 equipment model: Enterprise, Site, Area, Cell and Unit. Each location is identified in the system by: An identifier A location path, which locates the equipment within its hierarchy About Importing Common Locations, only the locations such as Enterprise, Site and Area can be referenced. Optionally their children can be imported too. About Private Locations, location hierarchies can be created by the user according to the S95 equipment model constraints.
5.3.9
Handling Properties
MM allows the creation of properties independently of the entity which will use them. This means that properties are considered as isolated objects which must be created and configured before be used for the association with MM entities. Additionally, properties can be grouped under property groups, which are userdefined. The basic information handled by a property specifies: Unit of Measure (UoM), for which all the most important UoMs defined in the global standard International System of units (SI) are available. Type Value, as variant, integers, floating points, strings, date time, decimals A general purpose description Some optional flag which indicate how the property will be used. Properties can be configured in order to be: Range, to specify range of values with lower and upper boundary Set, to specify a set of values Inheritable, which specify if the property can be inherited by lots and sublots when it is associated to a Material Class or a Material Definition A property can then be range and set, that is a set of range values can be specified for that property. Each new property is identified in the system by a unique identifier. After being defined, properties can be associated to the following entities: Material Class
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SIMATIC IT Material Manager Runtime Operations Material Definition, which automatically maps the properties of the related Material Class BOM BOM Item, which automatically maps the properties of the associated Material Definition Handling Unit Type Handling Unit, which automatically maps the properties of the related Handling Unit Type
5.4
5.4.1
Runtime Operations
Handling Lots
Once a Material Definition version is approved (i.e. its status is Approved), it becomes able to manage Lots and Sublots, which identify a specific physical amount of a material quantity. Normally, Lots handle the following basic information: Initial Quantity, the amount of material specified at the moment of the lot creation. Related unit of measure (normally inherited from the related Material Definition) Validity range in terms of time. Status Actual Quantity, the amount of material currently available In addition lots can be assigned to locations, by specifying an existing location path among the available Common or Private Locations. Each Lot is identified in the system by: Its unique identifier And the related Material Definition version Once a lot is created, it can be used as a physical representative amount of that specific Material Definition version and it is possible to use it to perform genealogy operations.
5.4.2
Handling Lot Status

MM provides a basic life cycle for Lots/Sublots composed of the following statuses: In quality check (qc) Released (rls) Approved (apvd) Available (av) In process (prcs)
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SIMATIC IT Material Manager Runtime Operations Blocked (blck) The available attributes for each status are:
Attribute Is Editable Description The lot configuration can be modified. It is possible to add property values, change lot name, description, property values and validity. The lot can be deleted. The lot is active. MM does not perform any check on this attribute. The lot can undergo to operations such as assemble, consume, supply, split, join, transform, etc.
Is Deletable Is Active Is Operable
By default, MM sets all attributes to true except for the Blocked status where the Is Operable attribute is set to false. This means that a Lot which is in Blocked status, it appears as locked and no operations can be performed on it: lot can not be moved, joined, disassembled, transformed, etc. The user can modify the default configuration of each status and eventually add other statuses to the system life cycle.
5.4.3
Consuming/Supplying Lot Quantity

One of the most important information handled by a lot is the quantity value, which quantifies the amount of material which is available. As to quantity, the basic operations are: Consume, when a certain quantity of material is consumed from the lot Supply, when a certain quantity of material is supplied to the lot Important These operations can be performed only on lots whose status has the Operable attribute set to true (i.e. the status is not Blocked).
For example, assume to manage a certain material by 1 Kg/Lot. This means that the initial quantity of each lot is normally 1 Kg. If during a certain operation you consume the 50% of a lot, the actual quantity of that lot is halved and in the next operations you have still the 0.5 Kg of that lot to consume. In addition, you can supply 0.5 Kg to that lot in order to restore the quantity to 1 Kg.
5.4.4
Working with Genealogy

Each lot can undergo some operations which determinate in the time the genealogy of the lot. Each time the lot undergoes an operation the history change is traced in the MM repository. Genealogy of a lot can be referred to as: Backward genealogy (the lots which made up a specific lot)
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SIMATIC IT Material Manager Runtime Operations
Forward genealogy (the lots created from a specific lot)
As to genealogy operations, each lot handles the following basic fields in its history: Operation Date, date and time when the operation has been performed Source Identifier, the source lot in the operation Target Identifier, the target lot in the operation Associate To, a custom string configurable before performing the operation; this string is generally used to indicate the cause of the operation Comments, additional remarks The available operations can be summarized as follows:
Operation Split Join Transform Assemble Purpose Splits a specific amount of material into another amount of material. Joins two or more lots to form a single lot Transforms a lot into another lot Assembles two or more lots into other lots
MM automatically checks and processes lot quantities as they undergo to the various operations.
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SIMATIC IT Material Manager Runtime Operations Important These operations can be performed only on lots whose status has the Operable attribute set to true (i.e. the status is not Blocked).
Splitting Lots
Split operation separates a source lot into n parts of a specific quantity. In this kind of operation, lots pertain to the same material definition. The user must specify the source lot to split and the target lots to generate by the split. Assume you want to split a lot into two parts. The split can be made upon: The entire quantity; this will divide the lot in two. A custom quantity; this will generate a lot of the specified quantity. The following diagram shows a split made upon the entire quantity (Q=n), in a simple use case:
The source lot whose quantity was Q=n, after the split, its quantity has been halved to n/2 and a new lot amounting to n/2 has been generated. The following diagram shows a split made upon a custom quantity (q=m):
In this case, the user has specified a custom quantity of m. After the split, a new lot which amounts to m has been generated and the original lot now amounts to n m. The Lot generated in the split operation, has the same characteristics of the old one. Optionally the user can specify if property values can be inherited from the related material definition or the source lot, and if the source lot must be deleted after the split.
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Joining lots
Join operation causes a list of lots related to the same material to become joined in a target lot. It can be seen as the opposite of the split operation. In this kind of operation, lots must pertain to the same material definition. The following diagram shows the situation before the join, in a simple use case:
The user specifies the source lots (Lot 1 and Lot 2) and the target lot (Lot 1). After being performed the operation, the source lots are removed as they become part of the target lot and the amount of the target lot becomes the sum of the source lots amount (Q=n+m):
Transform
Transform operation converts a list of source lots (also lots related to distinct materials) into a list of target lots. In this kind of operation, lots can pertain to distinct material definitions. During a transform operation a specified amount (or the entire amount) of the source lots is consumed and consequently it is produced the specified amount of the target lots. The following diagram shows the situation before the transformation, in a simple use case:
The target lot (Lot D) has an actual quantity (Q=z) and a target quantity (q=x). It must be generated from the source lots (Lot A and Lot B).
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SIMATIC IT Material Manager Runtime Operations After the transformation, source lots quantity becomes zero and Lot D actual quantity assumes the target quantity (Q=q=x):
Assemble/Disassemble
Assemble operation produces a lot putting two or more lots together. In this kind of operation, lots can pertain to distinct material definitions. A lot which has been assembled can be successively disassembled taking apart its constituent pieces. The user must specify the source lots and the target lot into which source must be assembled. The following diagram shows the situation before assembling, in a simple use case:
Source lots (Lot A, Lot B, Lot C) must assemble Lot D which has an initial quantity (Qc=t). After being assembled, the source lots are removed and the assembled lot amounts to the same initial quantity (Qc=t), but now, it is composed of distinct lots amounting to a certain quantity.
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The assembled lot can be successively disassembled taking apart Lot A, Lot B and Lot C.
5.4.5
Creating Handling Units

Handling units represent physical storage objects in MM. They can be associated to locations and then moved from one location to another. Normally thay are used to contain other handling units which, in turn, may contain handling units or lots. Normally, each handling unit handles: General information such as quantity, description Additional details such as Deliverer identifier, Order identifier, Batch identifier, Supplier, Produced/Delivery/Store/Evacuation Dates Transport-related information such as Transport, Carrier, Track Number Once an handling unit is created, it maps the properties of the related Hut type and, additionally, other properties can be added to it.
5.4.6
Charging/Discharging Huts
When an handling unit is created it is possible to charge it with a set of lots. In turn, a charged Hut can be discharged of its lots. A charge/discharge operation always traced in the Lot/HUT History with their Associate To string and Comments fields.
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SIMATIC IT Material Manager Runtime Operations As to charge/discharge operations, each lot handles the following basic fields in its history: Old Hut ID, the handling unit from which the lot has been discharged New Hut ID, the Hut into which the lot has been charged
5.4.7
Working with Hut Status

MM provides a basic life cycle for Huts composed of the following statuses: Advised Cleaned Delivered Empty Free Locked Occupied Reserved The available attributes for each status are:
Attribute Is Editable Is Deletable Description The hut can be modified. The hut can be deleted.
By default, MM sets all attributes to true except for the Locked status where both attributes are set to false. This means that a Hut which is in Locked status can not be modified or deleted. The user can modify the default configuration of each status attribute and eventually add other statuses to the system life cycle.
5.4.8
Moving Operation
When a Lot or a HUT is assigned to an existing Common or Private location it can be moved from it into another location. Normally, when a lot is charged into an handling unit MM keeps automatically trace of the movement of the lot from one location to another as the handling unit containing it is moved. A move operation is always traced in the Lot/HUT History with their Associate To and Comments fields. As to move operations, each lot handles the following basic fields in its history: Operation Date, date and time Old Location Path, the location path from which the lot has been moved New Location Path, the location path into which the lot has been placed
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SIMATIC IT Material Manager Using MM Display
5.4.9
Handling Property Values of Lots and Huts

At runtime, it is possible to set Material Lot property values fro those lots which are valid (i.e. their validity is not expired) and not in the Blocked status. The assignment of the property values must be done accordingly to the type of values the property can accept. If the property is set, the lot property can assume various values during the lot life cycle. If the property is range, it is possible to specify values which fall only within that range.
5.4.10
Reading the Lot History

MM keeps trace of the history about a certain lot as it undergoes the various operations. As to history, it is possible to retrieve all the operations perofrmed on a lot and its genealogy as well.
5.4.11
Working with Sublots

MM allows managing sublots of lots. Sublots are equal to lots and they can be managed in the same way as lots are. Normally the choice of using Sublots or not depends strictly by the context of the SIMATIC IT application. Generally, each lot can be composed of a series of sublots of a specific quantity, and in turn each sublot can be composed of other sublots.
5.5
Using MM Display
Material Manager is provided with a user-friendly graphical interface, the MM Display, which allows the user to take advantage of the functionality and perform manually all the engineering and runtime activities described in the previous sections.
5.6
Using MM GSI SIT Methods

Material Manager is also provided with a GSI interface which exposes all the methods and events required in order to manage entities directly from Production Modeler rules. The provided set of methods and events allows performing all the engineering and runtime activities as described in the previous sections and much more.
5.7
Importing Bulk Data through Fast Data Import

Material Manger provides the possibility to import a large quantity of data directly from XML file coded according to a proprietary format. This operation can not be performed from the MM Display, but it is possible to build a rule in PM which imports such a data through the SIT_FastDataImport method.
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SIMATIC IT Material Manager Importing Bulk Data through Fast Data Import This GSI SIT method allows synchronizing a huge amount of data in times relatively shorts. For example, the following items can be synchronized one-shot: 2500 BoM / 100 Items / 30 Properties 40000 BoM / 50 Items / 10 Properties 7000 BoM / 300 Items / 5 Properties
The input argument is provided through an XML string which indicates: The path of the data files containing the configuration about the entities to import Various filter conditions for the exclusion of some records specified in the data files. The filter condition is provided as in a Where SQL clause Various replace instructions for the change in the configuration of specific data The various properties to import specified by their ID Working modes Options In addition to the XML input string, the user must provide the data files (.dat) which store the information about the potential data which can be imported and a format file (.fmt) which specifies the format of the data using the same standard notation of BULK Insert operations of Transact-SQL. The following objects can be managed: Property Material Type Material Class Material Definition BOM BOM Item Each object is specified in the data file as a single record and each record must contain some basic information such as the object type and the object identifier: Additionally, it is possible to specify hierarchy of data relating an object ID to its father object ID. The allowed associations are those allowed by the logical relationships among the Material Manager entities: Properties with Property Groups Material Classes with Material Types Material Definitions with Material Classes BOMs with Material Definitions BOM Items with BOMs
5.7.1
Importing Data from External Systems via B2MML

Operations on the Material Model can also be performed starting from data coming from Business Level systems which use XML data structured according to the B2MML standard specification. Generally, MM provides a set of methods in order to manage such a process from Production Modeler rules:
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SIMATIC IT Material Manager Extending Material Manager with Custom Objects

Method SIT_AddB2MMLDataStructure Purpose Creates or replaces data in the MM repository according to a SIT structure B2MML-like. Creates data in the MM repository according to an XML file. Deletes data in the MM repository according to an XML file. Updates data in the MM repository according to an XML file. Retrieves data from the POM repository according to an XML file.
AddB2MMLData CancelB2MMLData ChangeB2MMLData GetB2MMLData
In particular, MM supports B2MML v2.0 schema definition (B2MML-V02Material.xsd) and it is provided also with a proprietary schema (B2MML-V02Material_SITExtension.xsd) which allows the extension of the standard B2MML with MM entities. Details about the XML data schema are provided in the Material Manager documentation.
5.8
Extending Material Manager with Custom Objects

MM allows the extension of Material Definitions, BOMs and BOM Items through custom data structures named Custom Objects. In brief: Custom data structure can be linked to Material Definition, BoM and BOM ITEM with a 1-to-many relationship. This means that a Material Definition/BoM/BomItem can have one or more than one record of a single custom data structure assigned. In order to exploit in the better way the 1-to-many relationship, it is now possible to specify a WHERE clause when updating custom data structure. This custom filter will be used by MM server, in conjunction to the native condition based on the PK, allowing the user to address a specific custom data structure linked to the Material Definition/BoM. It is possible to update and insert custom data structure in a single transaction. When using the ChangeB2MML method, by default the custom data structure are updated but you can choose for each single custom data structure to use an Add behavior. In this way while updating some custom data it is possible to add some other custom records to the Material Definition/BoM. The datetime data type is supported in custom data structures and like for other MM datetime fields, it support localization providing facilities to store UTC and local time drift (BIAS)
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SIMATIC IT Production Order Manager
6.1
The simplified architecture of the POM component is outlined in the following diagram:
As seen in the diagram, POM is based on a Multi-tier architecture (three-tier) in which: POM Display represents the Presentation Tier POM Server (one of the Production Application Servers) represents the Business Logic Tier The Components repository represents the Data Tier POM also exposes a GSI interface for interaction with Production Modeler. The integration among the Production Application Servers is performed at database level.
6.2
Basic Concepts
This chapter introduces some fundamental concepts related to the engineering and runtime entities which can be managed by Production Order Manager.
6.2.1
Order Hierarchy Model

POM allows managing Production Requests in terms of a Campaign tree structure where order data is organized through a hierarchy model of:
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SIMATIC IT Production Order Manager Basic Concepts Campaigns, which identify a specific production schedule and collect production requests within a specific time frame. Orders, which identify a specific production request made up of a subset of segment requirements. Entries, which identify a specific segment requirement to support production activities. The hierarchy model can be summarized as follows: 1. The father entity in the hierarchy is the Campaign. 2. A Campaign, in turn, groups the set of production requests identified as Orders. Orders can not be defined apart of a Campaign and a specific Order can belong only to one Campaign at a time (by default, POM groups Orders under the system Campaign named Default). 3. An Order, in turn, is made up of a set of segment requirements identified as Entries which can not be defined apart of an Order.
6.2.2
Time Frames
A time frame in POM is a means which allows defining identifiable time intervals in terms of days, months or years. Time frame can be used during the planning phase of the production requests to set the validity of a request in terms of time. During the configuration of a Campaign the validity is set to a specific Time Frame which limits the range of the Campaign Estimated Start and End Time (and also of the Campaign Actual Start and End Time). Orders too can be associated to a Time frame, which limits the validity range of the associated Order Estimated Start and End Time (and also of the Order Actual Start and End Time).
6.2.3
Families and Types

Orders and Entries may be simply grouped under custom categories, defined as: Family, which represents a collection of orders/entries with the same purpose Type, which identifies orders/entries with the same characteristics Families and types may be implemented in order to: Classify Orders and Entries by meaningful categories Simplify and specialize data retrieval at runtime Perform operations on Orders and/or Entries of specific families or types
6.2.4
Life Cycles
Each Campaign/Order/Entry can be associated to a Life Cycle, which is a set of: All the possible Statuses of an entity (e.g. "Initial", "To Be Scheduled", "Scheduled", "In Progress", etc). Status Transitions, indicating the possible state changes (e.g. from status "Initial" to status "To Be Scheduled")
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SIMATIC IT Production Order Manager Engineering Activities Each Status has Attributes which can be used to specify the actions which can be performed on the entity which is in that status. For example, an Entry can be deleted only if its status has the "Can Be Deleted" attribute.
POM provides three Standard Life Cycles, named "System", for Campaigns, Orders and Entries. The state machine defined by the Standard Life Cycle contains all the status definitions with the required attributes in order to manage correctly POM entities status transitions. Additionally, it is possible to implement Custom Life Cycles, Custom Statuses and Custom Attributes to fit better the application purposes. A Custom Life Cycle can use both System Statuses and Custom Statuses, and a Custom Status can use both System and Custom Attributes. A special set of System Attributes, named "aliases" (or "synonyms") which can be used relate a Custom Status to an equivalent System Status.
When a Campaign/Order/Entry is created, it is associated to a Life Cycle (the "System" Life Cycle is used by default) and to a Status (the "Initial" status of the "System" Life Cycle is used by default) but those associations can be modified at any time.
6.2.5
Custom Properties
POM allows the creation of custom Properties as single entities and then the free association of those Properties to various entities (Orders, Entries, Execution Equipments, Material Specifications and Material Specifications items, Equipment Specifications and Equipment Specifications items). According to the information intended to supply, a Property may represent numerical, textual and date time data and can be configured in various way depending on the specific purpose. Custom Properties may be implemented in order to: Provide entities with specific values at runtime concerning any useful data which is product-related or not. Undertake decisions at runtime on the base of specific values. Distinguish entities on the base of some assumed values. Triggering detectable events on the base of some assumed values. Manage quantities with multiple values and tolerance ranges.
6.3
This chapter provides a general but comprehensive overview of all the possible engineering operations which may be performed by an application using POM.
6.3.1
Creating Time Frames

The creation of Time Frames within POM is not a mandatory step, as Campaigns/Orders may be created without be associated to a validity time range.
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SIMATIC IT Production Order Manager Engineering Activities In any case, their use is helpful because allows the user in defining the required set of time range and reuse them in any moment during the creation/update of an Order. Time Frames must be created before their association to Campaigns and Orders. Once a Time Frame is created, it is identified in the system by its unique identifier which can be used during the creation of the Campaign/Order to make the required association.
6.3.2
Creating Families and Types

Creation of Families and Types is not a mandatory step, as Orders/Entries can be created without be associated to any Family or Type. Once a Family or a Type has been defined, it is identified in the system by an unique identifier to be used during the creation of the Order or Entry to make the required association. An Order or an Entry may have only one Family and/or Type associated. The association with one of the available Families and Types can be made at the moment of the creation of the Order/Entry and can be modified in any moment upon the Order/Entry configuration. Once Families/Types are associated to Orders/Entries it becomes possible to retrieve set of Orders/Entries by Family/Type ID, then performing specific operations on subset of Orders/Entries filtered by their Family or Type.
6.3.3
Defining Custom Life Cycles

Definition of Custom Life Cycles may be required depending or not if POM Standard Life Cycle satisfies the application requirements in terms of status attributes and transitions. Caution During the custom life cycle implementation, the automatic check on status attributes made by POM must be carefully considered in order to configure a status with the right attribute alias and actions. For example, if in a custom life cycle for Entries it is not included a status with the Can Be Archived attribute, data archiving can not be executed on those Entries associated to that life cycle. Generally, it is possible to define the following aspects of the Life Cycle: Statuses Attributes Transitions During the Status definition the user must specify: if the Status change must trigger an event. In this case, when an entity reaches that status, an event is triggered and can be intercepted in order to execute some specific tasks or make some checks on data. The attached attributes. Generally a Status has attached two kinds of attributes: an Attribute of type Synonym (or Alias) which is the "alias" of the status. For example, the status "Completed" has the synonym-attribute "Is Completed".
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SIMATIC IT Production Order Manager Engineering Activities
One or more Attributes of type Action which determinate the actions executable on the Status it self. For example, the Status "Completed" has the action-attribute "Can Be Archived" (a Completed entity can be sent to historical tables), but it does not have the action-attribute "Can Be Deleted" (a Completed entity cannot be deleted). The user may want to create a custom status - named e.g. "Finished" - which has different attributes, so that different actions are allowed or denied on an entity in that status. Finally, life cycles are characterized by transitions which specify the possible changes from one status to another. A transition is generally defined by: The starting status of the transition (known as "Status From", or "Current Status"), The target status of the transition (known as "Status To", or "Next Status"),, an associated Transition Attribute: in fact, more than one "parallel" transitions may be defined between the same statuses, and the Transition Attribute is used to distinguish them. The Transition Attribute is also used by some special POM GSI SIT methods (the ones which name contains the "SetNext" clause) to change the status of an entity without knowning the exact name of the next status (Note that, conventionally, if an attribute is used as Transition Attribute for a transition, it is also associated to the starting status, but this is not mandatory: for example, since the System Life Cycle for Entries has a transition which connects "Initial" and "To Be Scheduled" via the "Can Be To Be Scheduled" transition attribute, then the "Initial" status is also associated to the "Can Be To Be Scheduled" attribute. But if the user defines a custom transition between status X and Y via transition attribute A, it is not needed to associate attribute A to status X).
Important When the defining a Custom Life Cycle for Entries related to On Event Process Segments, be sure to include at least the following: - One status with the attribute Is Initial, where this status is the only one with this attribute in the life cycle's set - At least one status transition
Once created, a Custom Life Cycle is identified in the system by its unique identifier which can be used during the creation of the Campaign/Order/Entry to make the required association.
6.3.4
Creating Custom Properties

POM allows the creation of Custom Properties for general purpose to be associated to existing Orders and Entries. A Custom Property is generally characterized by the type of handled data (Numeric, String, Date Time) and the possible actions to be managed: Raise an event when the value changes (Event option)
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SIMATIC IT Production Order Manager Engineering Activities Record specific data in the POM repository when the value changes (Log option) Manage list of values (Multi Value option) Be associated to more than one group (Multi Group option) Additionally, each property can be configured with constraints which limit the values acceptable by the property itself. The constraint can be: Constant, if the property can only assume a specific value Set, if the property can assume only some specific values Range (only for numerical properties), if the value the property must assume can accept a certain margin of tolerance. Note: if a runtime value associated to a Property violates a constraint, a warning is generated. Once a Custom Property is defined in the configuration table, it is referenced inside the system by its unique identifier and type, by which it may be associated to any entity. Once defined properties can be associated to entities during the creation of the entitiesitself but their association can be modified in any moment. At runtime, properties associated to entities assume values which can be used for general purposes, like data processing, information tracking, or decision-making processes.
6.3.5
Creating Orders from PPR

Orders can be automatically created from the available Product Production Rules (PPRs) previously defined through PDefM. Important Orders can be created only from PPR versions which are in Approved status and for which the Health Check operation has been correctly accomplished. This means that all mandatory conditions of the Health Check must be verified. Such an Order is composed of as many Entries as the Product Segments defined in the PPR. Each Entry has its own Product Segment and the segment resources are copied exactly from the related Product Segment. In particular, an Entry associated to a Product Segment maps its: Material Specifications Equipment Specifications Execution Equipment Caution At least one Execution Equipment must be specified. In case of Standard Product Segments the Entry has also a reference to the related Process Segment and becomes able to dispatch the Process Segment in the Production Modeler environment. Note Once the order is defined, it is possible to apply some changes in the configuration and add and model other Entries as well.
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SIMATIC IT Production Order Manager Engineering Activities After their creation, the configuration of the specifications and execution equipment can be changed according to the requirements of the production request.
Product Requested Quantity

When creating the production order, POM requires the quantity to produce. This quantity must fall between the PPR Batch Minimum and Maximum Size, decided at the moment of the Product Definition:
BatchMinimumSize OrderQuantity BatchMaximumSize

Generally, the specific values of each Entry are computed at the time of instantiation of the Order, rescaling the corresponding values of the Product Segment by a scale factor. The Entry rescaled values are: Variable Duration term Material Specification Items quantities (except for those items whose Quantity Fixed flag is set to true) Equipment Specification Variable Quantity term Execution Equipment Variable Quantity term The scale factor is computed as the ratio between the Order Quantity (requested quantity for Order final product) and the PPR Batch Default Size:
ScaleFactor = OrderQuantity
BatchDefaultSize
As from the formula, if OrderQuantity is equal to the PPRBAtchDefaultSize the scale factor corresponds to the unit (1) and Entry values will be the same of the corresponding Product Segment values. Differently, if OrderQuantity is half of the PPRBAtchDefaultSize the scale factor corresponds to 0.5 and Entry values will be halved (a part of the material quantities with flag Quantity Relative that represent a percentage of the BOM reference quantity). After the Order is created it can be fully modified. This means, for instance, that at runtime, upon the order instantiation, previous of its dispatching, it is possible to change on which piece of equipment each entry must be executed which alternatives inside the specifications must be used and so on.
Scheduling and Dispatching Entries related to Process Segments

As to Entries which references common process segments (Production Modeler process segments which are created based on the Process-Segment class of the S95-Industry-Library), in order to be dispatched, the Entry must be in a status with Can Be Dispatched attribute. This means that for the system life cycle the entry must be in Scheduled status. The Entry can be configured in order to be dispatched in two modes: Automatically, then the Entry is dispatched automatically at its Estimated Start Time. Generally, this approach requires a scheduler application such as SIMATIC IT PDS-I or an ad hoc rule modeled in Production Modeler. Manually, then the Entry must be dispatched directly by the user via the POM Display or by activating a Production Modeler rule (typically the Background PO).
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SIMATIC IT Production Order Manager Runtime Operations Caution Even if Product Segments dependencies are mapped into Entry dependencies, POM does not provide any type of verification on the constraints implied by those dependencies. This means that the dispatch of the Entries must be performed with accuracy following the dependencies imposed to the Product Segments during the Product Definition phase. The dispatch of such an Entry has the consequence of starting the Process Segment in Production Modeler, thereby starting the related Rule of Rules. At the dispatch, Entry data is passed to the Process Segment: Input Parameters Value (passed to the Rule of Rules Input Arguments) Material Specifications Equipment Specifications As the Process Segment execution ends, values in POM are actualized and Material values are sent back to POM in the Actual fields of the Entry Material Specification items.
Working with Entries related to On Event Process Segments

In case the Entry is related to an On Event Process Segment (Production Modeler process segments which are created based on the On-Event-Segment class of the S95-Industry-Library) the action which causes the activation of the process segment is the status transition of the Entry. This means that when dispatching an Entry, a request of transition from status A to status B is sent to Production Modeler which activates the transition rule associated to that specific transition. During rule execution, the process segment remains busy and entry input data (input arguments and specifications) is processed by the transition rule. When rule execution terminates the process segment releases inherent resources and sends the results back to the order entry (return data and rule execution end status).
6.4
Runtime Operations
This chapter provides a general but comprehensive overview of all the runtime operations which generally may be performed on the engineered POM entities.
6.4.1
Modifying Order/Entry Quantity

At runtime it is possible to set quantities for specified Orders/Entries such as: Current quantity Produced quantity Reworked quantity Scrapped quantity These quantities are not managed by POM and they can be used in any moment to specify product-related data.
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SIMATIC IT Production Order Manager Runtime Operations Quantities can be typically set only when the Order/Entry is in a status with Can Be Updated attribute. For System Life Cycles this means that an Order must be in Initial or To Be Scheduled status. An option to force the quantities values independently from Order/Entry status is available for special use-cases. Quantities can only be set from Production Modeler, through a rule using the available POM GSI SIT Methods such as SIT_SetOrderQuantityList and SIT_SetEntryQuantityList.
6.4.2
Splitting Entries
At runtime, it is possible to split all the Entries which are in a status with Can Be Split attribute. About system life cycle, this means that the Entry must be in the Initial, To Be Defined or To Be Scheduled status. The split of an Entry produces a set of batches (Sub-Entries). By default, all the Sub-Entries produced during the split are scaled in proportion to the number of split entries. For example, if an entry is split in two identical batches, each SubEntry quantity will be halved.
6.4.3
Accessing Runtime Values

About runtime values POM allows: modifying the segment resource values of Entries in any moment retrieving Order/Entry property values in any moment
6.4.4
Handling Status Change

Status of Campaigns, Orders and Entries is a fundamental information at runtime, because many of the decisions taken depends on the status itself and operations available on Campaigns, Orders and Entries depends strictly on the attributes of the assumed status. POM provides the user with all functionality in order to change the status of the Campaign/Order/Entry manually or automatically.
6.4.5
Archiving Data
POM provides the users with the possibility of archiving data related to Orders dispatched at a specific time. To archive an order related to the specified entry ID, all entries (including the Background PO or Job associated to the Order) must be in a status with the attribute Can Be Archived. Data archives can be created about specific periods and backup can be saved on remote hosts.
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SIMATIC IT Production Order Manager Using the POM Display
6.5
Using the POM Display

Production Oder Manager is provided with a user-friendly graphical interface, the POM Display, which allows the user to take advantage of the functionality and perform manually all the engineering and runtime activities described in the previous sections.
6.6
Using POM GSI SIT Methods

Production Oder Manager is also provided with a GSI interface which exposes all the methods and events required in order to manage entities directly from Production Modeler rules. The provided set of methods and events allows performing all the engineering and runtime activities as described in the previous sections and much more.
6.7
Managing Operations through the Campaign Tree and Private Xml

POM provides another strategy of managing data, where the Campaigns are considered and used directly as huge trees made up of attributes and sub-trees. The user is able to specify only by an input argument the hierarchy of data to add/modify representing a Campaign with Orders and Entries and all related entities such as Properties, Material and Equipment Specifications, Specification Items and Execution Equipment, etc.. All these entities can be added and/or modified according to the configuration of the input argument. Two GSI methods allow this kind of data processing: SIT_ AddOrChangeCampaignTree, which uses a SIT_CAMPAIGN structure as input argument. In this case, the SIT_CAMPAIGN structure can be specified fully or partially according to the data to be added or modified. AddXmlCampaignEx, which uses an XML string as input argument written according to a private schema definition (AddCampaign2.xsd). The behavior of these methods is very simple: if the entity specified in the input is not present, it will be added; if it is, it will be modified with the new configuration. The search is performed recursively within the tree until the last leaf is reached. Within a SIMATIC IT application, rules using these methods can be implemented in many different ways and for various purposes. An example of usage may be a single rule which makes a set of operations on the Campaign Tree just using two steps: a Data Builder which: gets in input the required data the application may add/change (e.g. Entry Specifications, etc.) returns in output the SIT_CAMPAIGN structure configured according to the provided input
a POM GSI System Method Caller configured to call the SIT_ AddOrChangeCampaignTree with the input SIT_CAMPAIGN provided by the Data Builder step. The use of this method is very useful to manage data one-shot and with a very short variety of rules (may be just one as in the previous example).
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SIMATIC IT Production Order Manager Importing Data from External Systems via B2MML
6.8
Importing Data from External Systems via B2MML

As an alternative to creating Orders by generating them from a PPR, you can import a complete Order and Entry structure from ERP systems into POM repository starting from XML data structured according to the B2MML specification. The strategy of importing data from an ERP system is various and may change according to the application requirement. Generally, POM provides a set of methods in order to manage such process from Production Modeler rules:
Method SIT_AddB2MMLDataStructure Purpose Creates or replaces data in the POM repository according to a SIT structure B2MML-like Creates data in the POM repository according to a B2MML string Deletes data in the POM repository according to a B2MML string Updates data in the POM repository according to a B2MML string Retrieves data from the POM repository according to a B2MML string
AddB2MMLData CancelB2MMLData ChangeB2MMLData GetB2MMLData
In particular, POM supports B2MML v2.0 schema definition and it is provided also with a private schema named B2MML-V02ProductionSchedule_SITExtension_V02.xsd which allows the extension of the standard B2MML with POM entities. Details about the XML data schema are provided in the Production Order Manager documentation. In addition, it is important to ensure that the resulting data structure meets all requirements regarding Product Segment data structure for scheduling, and for this purpose POM gives all the flexibility to configure the Order Entries to which Product Segment are to be related.
6.9
Extending Orders and Entries with Custom Objects

For each Order/Entry it is possible to define a set of extension data structures stored in Custom Object tables. The tables are linked to the relevant Order/Entry by means of the Order/Entry primary key. The relation between Order/Entry and the extension data structure is 1-to-N: for each defined extension many instances (rows in the extension table) can be linked to the order. More than one data structure (different types of extensions) can be attached to the same Order/Entry. POM server extends the AddXmlCampaignEx method to insert/update custom order/entry extension under the same database transaction.
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SIMATIC IT Personnel Manager
7.1
Personnel Management
People represent one essential resource in the manufacturing system. They must be configured in the MES system, together with their characteristics, such as the skill of each person or of a group of people. The System must allow the assignment of shifts to people, and be aware and log each person's detailed activities during their working shift. Besides this, an MES System must also allow the integration of personnel data and production data: for example to check the personnel required for a task, or to log on which equipment, material lot, batch or order each person worked. SIMATIC IT Personnel Manager (PRM) handles personnel management within SIMATIC IT Production Suite.
7.2
Feature Highlight
The following information is an overview of SIMATIC IT Personnel Manager features: Configure Groups of People. Personnel single definitions can be grouped in order to have homogeneous management for a pre-defined set of people. Configure Properties for Groups. Properties can be defined at the Group level so that all people belonging to the Group inherit them. Configure Individuals. Single person profiles can be configured to have, when necessary, specific properties associated to the person themselves. Create Work Schedule Rules and Work Schedules Easily and Flexibly: Configure shifts, which are the basic building blocks for Work Schedules Configure periods (for instance a standard week) combining shifts and Holidays Configure rules to create Working Schedules (for example, one rule consists in the repetition of one period) Create Working Schedules
Importing and Exporting to/from ERP. All the data mentioned above may be imported or downloaded automatically from an ERP. Creation and Assignment of Work Schedules. Work schedules can be defined and then assigned to people or group(s). Association between Individuals and one or more SIMATIC IT User. Persons defined inside SIMATIC IT Personnel Manager might be associated to one or more user log-ins. Configure Personnel Constraints on Production tasks. It is possible to configure the number and properties of operators required to perform a step of a Production Operation. The Production Operation will also allow
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SIMATIC IT Personnel Manager Feature Highlight configuration of the actions that must be done at runtime, whether the constraint is satisfied or not. Data Collection. Collect each persons actual Working times, including the breaks. The component-based approach used by SIMATIC IT Framework allows integration of Personnel Managers with the System used in the Plant to collect the data about Personnel working times. Constraint Checking. For any Production Operation step on which the personnel constraint was configured, at runtime such constraint is checked. If the people configured for such step are not currently available, the Production Operation will take the appropriate actions as configured (E.g. send e-mails, or other messages to Operators, abort the current Order, to create a report). Specific Data Logging. Together with the Working times of each person, other Personnel Log data may be stored: the Equipment where the person was working the Production Order ID, or the Batch ID the material lot or sublot which the person is working on changes in the value of any Property associated to the person
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SIMATIC IT Shift Calendar
8.1
Overview
The Shift Calendar (SHC) component is able to manage calendar and working shift information that can then be shared among other SIMATIC IT Components. The basic functionalities of the SHC module are the management of a factory calendar, working time models (shifts) and calendar exceptions. The responsibility for defining associations between resulting calendars and calendar exceptions is maintained within each module managing such resources Consumers of SHC services are the PRM for the personnel resources, PM/BPM, PDS and PPA/DTM for equipment resources. Association between personnel and calendars is managed by PRM. Association between equipment and calendars is defined inside PM/BPM and then used by PDS and DTM. An association ID uniquely provided by SHC is used to keep track on other modules of the calendar entities associated with each resource instance. Calendar entities need not to be versioned or approved and once associated with a resource instance they are automatically linked with the current instance of such resource. The SHC server can be used to manage calendar information in an independent way, without the presence of all SIMATIC IT components, thus supporting the requirements for Lite bundle configurations as the OEE/DTM-Lite.
8-1
SIMATIC IT Data Integration Service
9.1
Overview
The primary purpose of SIMATIC IT Data Integration Service (DIS) is to enable the integration of the MES layer (level 3) with the Business layer (level 4). Data integration is made possible by means of XML message exchange through asynchronous and synchronous operations. Furthermore, DIS ensures compliancy with standard and proprietary formats enabling data import/export in SIMATIC IT by means of XML messages coded according to specific schema definitions (e.g. B2MML).
9.2
The following diagram shows the simplified architecture of DIS:
As from the diagram, DIS: Communicates with external systems by means of specific connectors. Communicates with Production Modeler through the PM GSI Connector. Communicates with SIMATIC IT S95 components through the B2MML connector.
9-1
SIMATIC IT Data Integration Service Connector Support Is provided with a Runtime Console in order to monitor project active connectors and threads at runtime. Is provided with a Management Console in order to configure the various projects in the engineering phase. Manages runtime data by means of a specific project database. Archives old data into a dedicated Backup Database.
9.3
Connector Support
The following table lists the various connectors provided by DIS, describing their purpose as well:
Connector PM Purpose Message routing with Production Modeler. Two connectors are available: B2MML PM COM Interface Connector (retained for compatibility) PM GSI Interface Connector (recommended)
Message routing with SIMATIC IT S95 components: Product Definition Manager (PDefM) Personnel Manger (PRM) Material Manager (MM) Production Order Manager (POM)
SAP
Message routing with SAP systems with the following formats: IDoc tRFC sRFC
File System MQSeries MSMQ COM HTTP
For reading/writing system files Communication with IBM Websphere Queuing System Communication with Microsoft Message Queuing System Communication with third party application which supports COM technology Allow applications to send requests to remote web servers and applications and provide or retrieve data with the ease of the DIS messaging-based communication system. Allow third party applications to connect to databases, execute stored procedures, functions and queries and read data Allows third party applications to exchange XML and text messages with SIMATIC IT DIS and other connectors Communication with custom .NET applications (either Windows or Web based applications)
ADO
Web Service
.NET
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10
SIMATIC IT Client Application Builder
10.1
10.1.1
CAB Environments
SIMATIC IT Client Application Builder (CAB) is a platform dedicated to the development of graphical user interfaces focused on displaying SIMATIC IT data. It consists of two environments: The engineering environment (CAB engineering): where GUIs are developed from within the Microsoft Visual Studio .NET through CAB components. GUIs are structured as WEB applications (CAB web pages), being ASP. NET the CAB underlaying technology. The runtime environment: where CAB applications are executed as requested by remote clients.
10.1.2
CAB Data Access Strategies

In the scenario exposed above, for simplicity's sake, two primary data access strategies can be outlined: Connected: connections with data source is continuous and web page refresh/reload is not required. In this case, CAB Web Server has the task of executing the CAB web page just the first time, unless new client requests are performed. Disconnected: connection to the data source is used only to retrieve data which is then processed on the CAB web server. New connection is required to check data source modifications.
10.1.3
Basic Runtime Architecture

The following diagram shows the simplified runtime architecture in the both scenarios exposed above:
10-1
SIMATIC IT Client Application Builder Software Architecture
As from the diagram: The client (relying on Microsoft Internet Explorer) displays Cab pages to the end user and sends requests either to CAB Server or CAB Web Server. CAB Server manages data in the connected scenario and it is also provided with specific objects allowing direct communication with Production Modeler and Real Time Data Server. Access to components is performed thorugh Production Modeler. CAB Web Server (relying on Microsoft Internet Information Services) executes CAB applications as by requests coming from clients. It handles data exchange in the disconneted scenario and communicates with Production Modeler (rule execution) and Real Time Data Server (spot reading). Components data retrieval is also made possible thorugh Smart Query Builder (SQB). Communication with CAB Server sometime is required.
10.1.4
CAB Portal
As of SIMATIC IT 6.3 SP1 the CAB Portal is released CAB Portal as an evolution of SIMATIC IT CAB, designed to reduce effort and time in creation of web-based client pages and projects. Easy and quick application development
10-2
SIMATIC IT Client Application Builder Developing CAB Web Pages Application reusability SIMATIC IT applications development standardization
10.2
Developing CAB Web Pages

Deleopment of CAB web pages is accomplished thanks to a customization of the Microsoft Visual Studio .NET. In this environment the user is allowed to program the code behind files by developing his ASP. NET solution through C# or Visual Basic. Basically the user need to perform only configuration operations during engineering time: dragging and dropping of objects, setting of some properties and so on. Whenever custom code is needed (for example to perform data validation or aggregation) it is possible to write code in the code behind file (which will be executed at web server side) or writing scripting code (which will be executed either at client side or at web server side). The following sections get an overview about the various objects and tools used to build CAB applications available from CAB engineering environment.
10.2.1
Data Access
As explained in the software architecture (see 10.1) data access is managed following two distinct approaches. These approaches take advantage of specific CAB objects: In a connected solution data is mainly managed using specific CAB data sources which are bound to specific CAB items, but also wide set of ActiveX controls are available. In a disconnected solution data is mainly retrieved via SQB using the SQBDataSource object and data access is performed executing rules on Production Modeler. Various classes and tools are available in order to guarantee data access and interaction with the various SIMATIC IT components (e.g. PPA, MSM, MM, RTDS, etc.).
10.2.2
Business Logic Execution

The interaction between Production Modeler and CAB is performed either in the connected or disconnected solution: In a connected solution the CAB PM Page Wizard tool is available in order to quickly generate web forms based on CAB PM Data Source, for the execution of rules in the PM environment. In a disconnected solution the CAB PM Rule Wizard tool is provided in order to generate C# classes for rule execution and event triggering in the PM environment. Also the PMMulticonnector class is provided to allow connection to plants distributed across several Production Modeler instances.
10-3
SIMATIC IT Client Application Builder Developing CAB Web Pages
10.2.3
Security
A specific library (SITCAB.Security) is dedicated to manage user access security to CAB web pages. The two main concepts in security (authentication and authorization) are handled by two dedicated modules: Authentication (for user recoginition and validation) is handled thorugh the CABAuthenticationModule class. Interaction with the authentication system is obtained by specific methods which allow the management of login, redirection and sign out process. Authorization (for user resource rights and page visibility) is handled thorugh the CABAuthorizationModule class. The purpose of this module is to ensure that a user who has already passed the authentication procedure, has an access level high enough for the requested page (or a part of it). If the access level is lower than the required one, the user is automatically redirected to the error page. Users are created and assigned to groups in the User Manager environment. User authentication relies on SIMATIC IT User Manager and thus CAB retains the same user rights and permission configurations as applied in the User Mangement environment. Before using these two modules a system configuration is required by configuring the dedicated file web.config. This file allows declaring the modules and configuring some basic security parameters.
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11
SIMATIC IT Historian
11.1
Overview
The Historian component allows the efficient archiving of huge amounts of historical data collected from the active plant. Such data are stored on a preconfigured set of Online Databases that are cyclically managed in order to limit the total size of each online database. Each time the total amount of online data exceeds a preconfigured threshold, one or more online databases is put offline and becomes part of the historical data set. A separate Config Database contains the information and metadata about the historical data gathered from the plant.
11.2
Plant Performance Analyzer

Here follows a summary of the features provided by the most important component of Historian, Plant Performance Analyzer: Project management activities: Versioning management Plant import from BPM Plant definition (if not imported) Data sources definition Elaboration task definition (algorithms and triggering mode) KPI (Key Performance indicators) definition RTDS (Real Time Data Server) PDA (Process Data Archive) PPA archives ODBC OPC-HDA WinCC Messages WinCC Tag Logging (no longer accessed via OPC-HAD) SCI (Simatic Control Interface) as data source via RTITF for Simatic Batch. Using SCI there is no need to use OPCHDA Data recovery management from the above mentioned data sources (from RTDS only upon specific user-defined configuration)
Data acquisition from different data sources:
Data elaboration by means of pre-defined functions and VBScript custom code: Pre-validation functions Post-validation functions Pre-defined statistical functions
Data elaboration triggering:

SIMATIC IT V6.3 SP1 A5E01140770-01 11-1
SIMATIC IT Historian Historian Data Display (HDD) On data change On Event Cyclically (on time) KPI results Out of bound results
Event notification:
The PPA component is responsible for managing EBR (Electronic Batch Recorder) functionality when associated to SIMATIC Batch by means of a specific programmatic interface. PPA can be also configured in order to store WinCC messages in custom data structure defined by the user in order to organize the archived data in an easy-touse way.
PPA sub-components
PPA also supports the integration with PCS7/Simatic Batch: these are not products part of SIMATIC IT but within the Siemens A&D product portfolio a direct integration path is provided towards the SIMATIC IT environment. Functionalities include: EBR functionality makes PPA able to archive all procedure elements of a batch execution WinCC messages collection makes possible to configure custom specific data filters in order to collect messages provided by WinCC system and are store them in dedicated custom tables to allow further processing of these raw data. Another task of PPA when integrated with Batch is the archiving of Batch related AT/ESIG (Audit Trail / Electronic Signature) information into CS database.
11.3
Historian Data Display (HDD)

The HDD component is responsible for visualization of each data archived by LTA. It is an Active-X, which act also as an Active-x container where several different Active-X can be embedded. The HDD can be used in two different ways: 1. As a self-consistent component; this exposes to each contained Active-X, the connection to the Application Server (HDDAps), which manage the physical connection to LTA or PDA (Process Data Archive). In this case all the contained Active-X get data from the Application Server. As self-consistent component HDD implements also a configuration Wizard by means it is possible to configure itself and the contained Active-X. 2. As a stand-alone Active-X component that exposes a set of automation interfaces in order to be used as a display component fed with data provided by an external application. In this case the Application Server isnt activated and the Configuration wizard isnt loaded. It is up to the external application to provide the needed business logic for configuring the component and for managing the data retrieving.
11-2
SIMATIC IT Historian Historian Data Display (HDD)
HDD sub-components
The Active-x objects currently available are the following: HDDX displays archived data in trend format offering different display option in order to allow trends comparison. BgViewer displays archived data in bar graph format. Production Viewer displays production data contextualized with corresponding Batch data or Production Key data. The batch data are retrieved from the EBR (Electronic Batch Recording) archive. Message Viewer displays archived Message data optionally contextualized with corresponding Batch data
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Preface Table of Contents Overview Production Information Management

SIMATIC IT 6.3 SP1

Siemens AG Automation and Drives Postfach 4848 90437 NRNBERG GERMANY

Copyright Siemens AG 2008 Technical data subject to change

Basic knowledge required

Where is this manual valid?

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SIMATIC IT V6.3 SP1 A5E01140770-01

SIMATIC IT Training Center

SIMATIC IT Service & Support

Software Update Service (SUS)

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Technical Support Service (TSS)

Access to the TSS

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5.5 5.6 5.7 5.8

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Manufacturing Execution System

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Overview General Architecture

A 3-Tiered Distributed System

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Overview General Architecture

Layered Service System

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Overview Main Functionality

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Production Information Management

Generic Activity Model

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Defining Operations Capability (Production Resource Management)

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Production Information Management Defining Operations Capability (Production Resource Management)

Equipment Resource Information Management

Interfaces to Equipment Management

Material Resource Information Management

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Interfaces to Material Management

Defining Operations (Product Definition Management)

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Production Information Management Defining Operations (Product Definition Management)

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Interfaces to Product Definition Management

Defining Operations Request (Detailed Scheduling and Dispatching)

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Interfaces to Production Dispatching

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Production Information Management Production Execution Management

Production Execution Management

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Production Information Management Production Execution Management

Collaborative Manufacturing (Integration Strategies)

Business Level Integration

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Production Information Management Production Execution Management

Management Level Integration