Ad ances in Elec ical and Elec onic Enginee ing
120
IMPLEMENTATION OF INFORMATION SYSTEMS IN MANUFACTURING
AREA
P. Peniak
a, b)
a) IT manage , IT di ision Con inen al Ma ado s. . o., T. Vanso ej 1054/45, Púcho , Slo akia
b) Depa men o Con ol & In o ma ion Sys ems, Facul y o Elec ical Enginee ing, Uni e si y o Žilina, Uni e zi ná 1,
010 26 Žilina, e-mail: pe e .peniak@con i.sk
Summa y
Pape deals wi h new ends ega ding implemen a ion o In o ma ion sys ems as one o he mos impo an pa s
o manu ac u ing in as uc u e. The main a en ion is paid o Manu ac u ing Execu ion Sys ems and Shop Floo in eg a ion
ega ded om he iewpoin o hei implemen a ion, manu ac u ing unc ions and in eg a ion.
1. INTRODUCTION
Indus y is mo e and mo e echnology d i en. The
ollowing decade has o be he e a o IT enabling
alue c ea ion. Changing om being an in e nal
se ice p o ide is one o he majo asks o IT.
In o ma ion Technologies ha e been conside ed as
suppo unc ion which is no di ec ly in ol ed in
he co e business and alue c ea ion p ocess. The
success o IT is de ined by he success o he
business. By ha co esponding key pe o mance
indica o s (KPI) shall be used o de ine and ack
unc ional and p ojec success. The e is a need o
change in he app oach o implemen ing new IT-
solu ions based on
 speed o change,
 inno a ion capabili y,
 adap a ion o new p ocesses, new unc ions,
new ools,
 he in ensi y o usage o he p o ided so wa e,
 he abili y o alue c ea ion.
Co e ac i i ies and compe ence o un a
comp ehensi e ope a ing model o IT ha e o be
iden i ied including skills, me hods and needed
p ocesses. IT akes o e mo e and mo e
esponsibili y as a pa ne o i s cus ome s in he
de ini ion and ope a ion o bes in class p ocess
chains a easonable cos . An IT compe ence cen e
a e o p o ide p oac i ely all know how,
compe encies, esou ces, ools & sys ems o de ine
and suppo he p ocesses needed in he
co esponding business unc ions, see Figu e 1.
Fig. 1 Example o IT CCs ( Compe ence Cen e)
The in o ma ion sys ems ha e o suppo all he
main business p ocesses which a e necessa y o
unning o business and o enable company
ope a ions in global en i onmen . In addi ion he
manu ac u ing a ea is becoming mo e and mo e
dependen on IT. IT is esponsible no only o
alue c ea ion and suppo manu ac u ing p ocesses
bu mus ake in o conside a ion high a ailabili y
and necessi y o con inual p oduc ion ope a ions.
Any majo ail o IT could lead immedia ely o
s opping o p oduc ion and his aspec is mo ing
posi ion o IT o he one o mos impo an pa o
manu ac u ing in as uc u e. The e o e an
app op ia e implemen a ion o In o ma ion sys ems
is one o he key ac o s o business success in
manu ac u ing a ea.
2. INFORMATION SYSTEMS FOR
MANUFACTURING
Manu ac u ing as a pa o o e all en e p ise o local
company mus be in eg a ed in o gene al business
p ocesses ha a e suppo ed by ERP (En e p ise
Resou ce Planning) In o ma ion Sys em. ERP is an
indus y e m o in eg a ed, mul i-module
applica ion so wa e packages ha a e designed o
p o ide in o ma ion sys em o mul iple business
unc ions as o de en y, gene al ledge , pu chasing,
wa ehousing, anspo a ion, human esou ces and
manu ac u ing. Wi h help o ERP companies can
s anda dize business p ocesses and each easily he
bes p ac ices. In addi ion ERP sys em has o
p o ide basic ame o manu ac u ing suppo
including
 budge managemen ,
 a icle calcula ion,
 p oduc speci ica ions,
 Bill o Ma e ials (BOM),
 basic ou ings o p oduc s ia machine chains,
 main enance me hods, and
 quali y sys em de ini ion.
ERP sys ems a e ypical ansac ion o ien ed
sys ems whe e one business unc ion consis s o
se e al IT ope a ions logically bound o a
ansac ion. ERP sys ems a e ocused on ansac ions
whose ime scope is de ined acco ding o epo ed
pe iod such as mon hs, days, shi s leading up o
minu es.
CC
Manu ac u ing
CC
Ma ke ing &
Sales
CC
R & D
CC
Supply Chain Managemen
CC
Manu ac u ing
CC
Ma ke ing &
Sales
CC
R & D
CC
Supply Chain Managemen
Implemen a ion o in o ma ion sys ems in manu ac u ing a ea
121
The di e en app oach has o be aken in
manu ac u ing a ea. IS sys ems do no only p o ide
in o ma ion o con ol o p oduc ion acco ding o
es ablished ules, hey ha e o be also designed o
cap u e eal- ime da a as i is c ea ed, and help
manu ac u e s ake ac ion in he momen , based on
ha in o ma ion. The plan loo (so called
ShopFloo ) needs a e unique and equi e an "ac i e"
sys em ha p o ides immedia e de ec ion and
no i ica ion o any non-con o mance e en wi h
ala ming. P oduc ion manage s equi e a sys em ha
will manage a iances, p oblem inspec ion and
esolu ion, and con inuous imp o emen p ocesses
while en o cing p oduc ion ules, ope a o
ce i ica ions, and co ec i e ac ions. The ime ac o
mus be adjus ed acco dingly and should be close o
eal- ime esponse [in seconds]. The di ec
applica ion o ansac ional ERP sys ems o
men ioned se ices in manu ac u ing a ea is no
easily managed and b ings a lo o conce ns. The e
was a need o speci ic unc ions and IT se ices ha
could no be co e ed only by ERP.
The e o e he e was a need o in oduce middle-laye
so called MES (Manu ac u ing Execu ion Sys ems)
o p o ide a b idge among En e p ise sys ems (e.g.
ERP sys ems such as SAP, PeopleSo ), and he
au oma ion sys ems con olling manu ac u ing on
he plan loo (Machine Con ol). This sys em
shall also sol e he ime ac o issue ans o ming
ime o ope a ions be ween ansac ions o ERP
sys ems and eal- ime communica ion ha is
equi ed by machine con ol sys ems. The p oposed
py amid a chi ec u e o in o ma ion sys ems
including ime ac o is shown in Figu e 2. The
de ailed block diag am o unc ions ha a e p o ided
by ERP, MES and in eg a ion laye o
manu ac u ing is desc ibed in Figu e 3.
Fig. 2 Py amid a chi ec u e o manu ac u ing IS
MES sys ems shall p o ide he ollowing unc ions
o manu ac u ing:
 Dispa ching o manu ac u ing p ocesses in
ShopFloo and ope a o ins uc ions.
 Comp ehensi e, accu a e and imely p oduc ion
and in en o y da a.
 Elimina ed manual eco d keeping, imp o ing
he accu acy and o ganiza ion o he da a on he
shop loo .
 P o ided ull p oduc aceabili y and genealogy
co ela ing wo k o de s (BoM, Recipes) wi h
p ocess da a.
 In eg a ed quali y, p ocess da a collec ion and
quali y analysis (quali y p ocesses).
 Repo ing unc ions like summa ies, u iliza ion,
down ime, p oduc yields, sc ap, in en o y and
p oduc ion con ol (on-line epo ing).
ERP
MES
&
ShopFloo
In eg a ion
Machine Con ol
(Au oma ion)
ERP
[ > 1 min
]
[ < 20ms]
[
 1 s]
En e p ise Resou ce P la nnin g
Shop loo
H is o ia n
R ea l T im e
unc ion s O pe a o In e ace
I/O
c om m u nic a ion s
B a ch con o l P oc e ss & M a ch ine Dia gnos ics
P ocess co n o l
R esou ce
Allo ca io n
A ic le calc ula io n
Dispa c h ing
Onlin e epo ing
F ull P od uc T a ca bili y
D a a A cq uis i io n
SP C
Op e a o ins uc io ns
M a s e D a a
Re c ipe s / BO M / R ou in gs Bas ics
Sch eduling & Se qu e ncing
M ain en ance P o ce sses
Qu a li y P oc es ses
Bu dg e M g .
Plannin g
Q ua li y S ys em s D e ini ion M ain en a nce M e h ods
Re cipes / BO M / Rou in gs P od uc ion
ER P
In eg a ion
La ye
M anu ac u ing
Execu ion
En e p ise R esou ce Pla nnin g
Shop loo
H is o ia n
R eal T im e
unc ion s O pe a o In e ace
I/O
c om m u nic a ion s
B a ch con o l P oc e ss & M a ch ine Dia gnos ics
P ocess co n o l
R esou ce
Allo ca io n
A ic le calc ula io n
Dispa c h ing
Onlin e epo ing
F ull P od uc T a ca bili y
D a a A cq uis i io n
SP C
Op e a o ins uc io ns
M a s e D a a
Re c ipe s / BO M / R ou in gs Bas ics
Sch eduling & Se qu e ncing
M ain en ance P o ce sses
Qu a li y P oc es ses
Bu dg e M g .
Plannin g
Q ua li y S ys em s D e ini ion M ain en a nce M e h ods
Re cipes / BO M / Rou in gs P od uc ion
ER P
In eg a ion
La ye
M anu ac u ing
Execu ion
Fig.3 Block diag am o Manu ac u ing IS unc ions
Ad ances in Elec ical and Elec onic Enginee ing
122
The e is also an In eg a ion laye ha c ea es
logical link among MES and he con ol sys ems in
ShopFloo . This laye mus in eg a e a ious
sys ems in o one common subsys em which p o ides
in o ma ion necessa y o manu ac u ing p ocesses
such as

I/O communica ions,

eal- ime unc ions,

da a acquisi ion,

p ocess con ol and ba ch con ol,

ope a o in e ace (HMI), and

machine diagnos ics.
The ShopFloo con ol sys ems (PLCs, machine
PCs, Indus ial PCs, con ol applica ions) a e
connec ed o na i e indus ial ne wo ks o ins ance
ieldbus echnologies like P o ibus, De iceNe ,
CAN o Indus ial E he ne . Fo in eg a ion wi h
MES he e a e special ga eways used ins ead o
a di ec communica ion. The e a e many ways how
o in eg a e MES h ough he ga eways wi h con ol
sys ems in ShopFloo ins ead o di ec
communica ion. The o me solu ion was based
mainly on he in e na ional s anda d MAP/ISO and
he p o ocol MMS (Manu ac u ing Message
Speci ica ion) ha used i ual de ice model o
each manu ac u ing de ice and in oduced mapping
o physical elemen s o any indus ial de ice o
logical a iables (Va 1..Va 3) ha a e accessible
ia ne wo k see Figu e 4. By using di e en
ne wo ks a ga eway has o suppo se e al d i e s
o each applied indus ial ne wo k p o ocol (Fig.
4a) o he e has o be used any open solu ion
suppo ed by all de ices o example DDE (Fig. 4b).
Fig.4 Ga eway as In eg a ion laye o MES
Nowadays s anda d OPC is widely accep able in he
a ea o indus ial in eg a ion, which is used o
in eg a ion pu poses and as open model o
communica ion. We can ind he ollowing me hods
o implemen a ion o ga eways

OPC (Objec Link Embeging o P ocess
Con ol)

DDE (Dynamic Da a Exchange)

DCOM (Dis ibu ed COM)
OPC is being used ins ead o MMS as de ac o
s anda d o indus ial in eg a ion o con ol and
ieldbus sys ems wi h any kind o hos sys em o
complex in o ma ion sys em like MES o ins ance
p oduc wi h OPC Se e o machines di ec ly
suppo ing OPC and OPC p oxy o de ices wi hou
OPC suppo , see Figu e 5.
Fig.5 MES OSI wi h OPC in eg a ion laye
3. IMPLEMENTATIONS OF IS IN
MANUFACTURING AREA
The implemen a ion o in o ma ion sys ems in
manu ac u ing a ea and Shop Floo equi es he
speci ic condi ions and building blocks (see Figu e
6) in o de o suppo eal- ime p ocesses and
machine con ol. MES sys ems mus be a ailable in
eal ime so ha machine con ol le el could ge
necessa y in o ma ion o p oduc ion con ol, ecipe
managemen e c. The e o e MES sys ems a e o be
implemen ed in local DPCs in con as o ERP
sys ems which can be hos ed in cen al DPCs and
accessed ia WAN. The las decade was
signi ican ly in luenced by in oduc ion o he new
echnologies, p o ocols and s anda ds ha causes
a majo change in IT indus y. We can summa ize
hem as ollows:

Consolida ion o ha dwa e in as uc u e
(Clus e s, SAN, G ids,...) wi h ocus on
a ailabili y, eliabili y and o e all suppo o
ope a ions,

Applica ion o da abase echnologies (SQL)
wi h eal- ime suppo and ail-sa e echniques,

Using o open s anda ds o in e acing o
di e en p oduc s and solu ions (OPC,
XML,...),

In oduc ion o e ec i e IT ope a ions and
p ocesses ( igh sou cing, ITIL/ITSM),

Consolida ion o DPCs (Da a P ocessing
Cen e) in o de o educe complexi y and o
p o ide eliable in as uc u e o ERP sys ems
and MES,

Using o communica ion echnologies wi h
suppo o SLA (Se ice Le el Ag eemen ),

T acking o ma e ial low wi h using ba codes
and RFID (Radio F equency Iden i ica ion).
SAP
OPC Se e
OPC
OSI
ODBC
Machine
Con ol
OSI
P ocess
Book
OSI
OPC
Clien
Fac o y
Floo
In e ace
Machine
Con ol
In ellu ion
PP:PI
In ellu ion
SAPODA
Implemen a ion o in o ma ion sys ems in manu ac u ing a ea
123
The example o IS implemen a ion in manu ac u ing
is shown in Figu e 7. ERP sys em (SAP) is
implemen ed in cen al DPC wi h using o he
clus e echnologies and SNA (S o age A ea
Ne wo k). ERP is connec ed wi h se e al plan s ia
WAN. Local DPCs o plan s hos local MES ha a e
connec ed ia OPC/ indus ial E he ne o ia
speci ic ga eways wi h machine con ol laye and
ieldbus.
Fig. 7 Example o IS implemen a ion o manu ac u ing
4. CONCLUSION
In o ma ion sys ems a e one o he mos impo an
pa s o manu ac u ing in as uc u e. They mus be
implemen ed in an app op ia e way o secu e and
enable necessa y p ocesses and allow alue c ea ion.
They will ha e o coope a e mo e and mo e wi h
con ol sys ems in ShopFloo and missing unc ions
and se ices in s anda d ERP sys ems will ha e o be
comple ed by using MES. MES will be a key
elemen in in eg a ion wi h machine con ol and will
be implemen ed in local DPC in con as o ERP
sys em. As well ieldbus and con ol le el will be
d i en o open communica ion and se ices wi h IS
ia open and accep ed s anda ds such as OPC.
REFERENCES
[1] DAVENPORT, T. H.: Mission c i ical: ealizing
he p omise o en e p ise sys ems. Bos on, Mass.
Ha a d Business School P ess; 2000, ISBN
0875849067
[2] MAHALIK, N. P.: Fieldbus echnology,
Indus ial ne wo k s anda d o Real – Time
Dis ibu ed Con ol, Sp inge , 2003
[3] ARC Ad iso y G oup: Manu ac u ing execu ion
sys ems also equi ed o ex end he alue o an
ERP sys em, San Jose, CA – Feb ua y 17, 2005
GATEW
Cen
al DPC
WAN
SAN
ERP
MES
Local DPC Plan 1
ShopFloo
Local DPC Plan n
Middlewa e
Componen s
In eg a ion
le el
Da a-
managemen
IT Pla o ms
Se e s
Desk ops
Comm
Se ices
Comm..
P o ocols & in .
Ne wo k
In as uc u e
Thin clien s wi h Windows WP, Linux,….
HW RISC/Win el (Clus e s, Blades, SANs), SW OS (UNIX, WINTEL)
OPC, WebSphe e, BS a ,…..
SQL DB, XML, Da aWa ehouses, OLAPs
TCP-IP, Secu e DHCP, DNS
E he ne ( 10/100 Mbi and Gigabi , 10G), WLANs(802.11x)|,
WANs (MPLS)
G oupWa e, Email , LDAP, ADS…
Secu i y
MES, MMS/OPC/DDE ga eways
P o ibus, De ice/Con ol Ne , E he ne IP(CIP), MMS…..
Fi ewalls, An i i us p o ec ion, VPN/VLAN wi h IPSec
Au oma ion
MACHINE
CONTROL
MES/ERP
Middlewa e
Componen s
In eg a ion
le el
Da a-
managemen
IT Pla o ms
Se e s
Desk ops
Comm
Se ices
Comm..
P o ocols & in .
Ne wo k
In as uc u e
Thin clien s wi h Windows WP, Linux,….
HW RISC/Win el (Clus e s, Blades, SANs), SW OS (UNIX, WINTEL)
OPC, WebSphe e, BS a ,…..
SQL DB, XML, Da aWa ehouses, OLAPs
TCP-IP, Secu e DHCP, DNS
E he ne ( 10/100 Mbi and Gigabi , 10G), WLANs(802.11x)|,
WANs (MPLS)
G oupWa e, Email , LDAP, ADS…
Secu i y
MES, MMS/OPC/DDE ga eways
P o ibus, De ice/Con ol Ne , E he ne IP(CIP), MMS…..
Fi ewalls, An i i us p o ec ion, VPN/VLAN wi h IPSec
Au oma ion
MACHINE
CONTROL
MES/ERP
Fig. 6 Building block o ERP and MES o manu ac u ing