Software architecture for the MES of the future

The factory of the future will face great challenges. One of these challenges is to record all data necessary and thus create the basis for a digital image of production. However, sensors, machines and systems only supply raw data. People on the other side want answers to specific questions. Suitable methods are needed to derive usable information from the digital basis and present it as answers as requested. Additionally, the rapidly increasing number of players (sensors, data suppliers and applications) are virtually crying out for an innovative architecture that is open in all directions.

By completely mapping the real physical world in digital form and establishing efficient control loops, production companies are striving for greater transparency and efficiency - in the spirit of Industry 4.0 and the Internet of Things. MIP offers the possibility to link systems, to model objects and to display and integrate the respective processes with high flexibility. The objective is to ensure an overall interoperability of all processes and systems.

What remains is the gap between raw data in the shop floor and the information requirement of the user and IT system. Only through a suitable compression, aggregation and accumulation of data can useful information be generated. That is the task of today's Manufacturing Execution Systems (MES). The challenges for such systems are now becoming more and more complex. The production-oriented departments need applications that include a growing variety of functions. As a consequence, the systems must offer a higher modularity and flexibility. The task to realize a standard solution that can cope with all these demands is challenging.

As a necessary consequence, an open integration platform is needed to link MES components and other production-related systems in a standardized way. Such a platform would fulfill many of the above-mentioned requirements and enables the provider-independent use of any type of application (e. g. MES, ERP, PLM,). Besides that, completely new cooperations between development and implementation partners may arise.

Manufacturing Integration Platform

With MIP, MPDV presents an open platform that offers a suitable environment for production-related applications and at the same time enables a complete digital transformation. MIP is:

• Integrator for standard applications from different suppliers
• Basis for the integration of specific applications
• Requirement to seamlessly embed in-house developments

With this platform the user can combine in-house software developments including individual solutions and the available standard applications out-of-the-box. The user can decide at any time on the in-house development and external solution ratio. At the same time, the platform ensures access to local resources and the ones linked via the Internet of Things.

A production company has several machines. The machines and their master data, the description of the produced articles and all work plans are stored in the MIP. The real machines are connected to the corresponding, digital image with so-called MIP Add-Ons. Data is continuously recorded and stored in the MIP. If orders are now created in the ERP system, they are also transferred to the MIP via another MIP Add-On. The production planner can now schedule when orders are made and specify the machine using a Manufacturing App (mApp). The resulting assignment is stored in the MIP and other shop floor mApps can display the orders to be produced at the corresponding machine. If you want to log on an order, you call the mApp in the shop floor via MIP. From now on, all recorded real time data are assigned to the corresponding machine and the logged order. An evaluation mApp can directly access the order data. As an alternative, an MIP Add-On is assigned to first compress the data and then to calculate required KPIs.

The above-described procedure would also be possible using an MES today, but only if all components would derive from one single source or if the components had been integrated in one system. However, the increasing complexity in today's production asks for a more flexible solution that combines components and applications of different origin. The critical prerequisite is an open system structure that can be guaranteed by the Manufacturing Integration Platform.

Prof. Kletti, can you tell us why the MES experts from MPDV have been working on a new platform approach for some time while the MES HYDRA is still well positioned on the market?

This is correct in principle. However, we are increasingly observing that production companies want to integrate their own applications or to connect third-party systems, of course setting aside the customary ERP connection. Business-wide networking of production and IT systems is also increasingly in demand. Thus we conclude the need for a new, open platform architecture for MES tasks. Therefore, we will have open concepts for production-oriented IT systems in future. Probably in addition to the classic MES systems.

What is the difference between an open platform and an MES system like HYDRA?

With an MES like HYDRA, companies can capture data both today and tomorrow, thereby controlling and optimizing their own production. With the new Manufacturing Integration Platform (MIP), all objects relevant to production are kept together with their data in a joint data base. Apps of all kinds can access these objects and their data flexibly through standardized methods and functions. The plausible spectrum of functions far exceeds the extent of today's MES systems. In particular, the underlying interoperability allows the user to integrate any applications and systems via the platform. This is exactly what is meant by accessibility in all directions. Ultimately, the MIP is an innovative variant to implement an MES.

What added value does your Manufacturing Integration Platform offer compared to other platforms that currently spring up like mushrooms?

Correct, you can spot platforms everywhere. The MIP stands out as it is not all about the availability and distribution of data, but it is rather a digital image of the production and all related data. At the core of the MIP, all objects are represented in a standardized manner, which allows a large number of apps to work independently of each other. Most other platforms only offer the option to exchange data. The meaning of the data is not necessarily known. The MIP is based on a semantic understanding of the data. If an app speaks of an order or a machine, it is clearly defined what is meant. This is an important requirement for the success of such a platform, especially for the integration of applications from different providers.

Most other platforms can be either located in the automation or in the management environment. There is currently no platform for the intermediate level on which MES operates today. This is precisely why we are pushing ahead with the development of the MIP.