Case Study in the Challenges
of Integrating CNC Production
and Enterprise Systems
John Michaloski
NIST
ISA EXPO October 2005
United States Department of Commerce
National Institute of Standards and Technology
Manufacturing Engineering Laboratory
Intelligent Systems Division
OMAC HMI Working Group Perspective
HMI Subsystem
Human
View
Control
OMAC
Model
(Data and
Events)
Machine Controller
Controller
Plant
Asset Mgt
Machine
Capabilities
Machining
Feedback
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Problem
“Design Anywhere, Build Anywhere, Support
Anywhere” requires worldwide enterprise connectivity
across design, manufacturing, distribution, and
maintenance.
David Humphrey, ARC Advisory Group, commented,
“… customers really want: real interoperability
between production and enterprise systems with little
or no integration.”
Can we realize real interoperability between
production and enterprise systems with little or no
integration, using OMAC and OPC concepts?
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
OPC Integration Technology
Machine Controller
HMI Subsystem
Human
View
Control
OMAC
Model
(Data and
Events)
OPC
Server
Controller
OPC
Client
Plant
Asset Mgt
Machine
Capabilities
Machining
Feedback
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
OMAC HMI OPC Strategy
OPC does I/O based on item tags



OPC does not define application item tag names
OMAC could standardize on required item tags
List of needed OMAC HMI data items based on application
requirements
Strategy is to create named item tags since OPC
provides communication mechanism, but no
application layering
Item tags could be groups by purpose: DA, commands,
machine configuration, maintenance/diagnostics, etc.
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Data Point Mapping
Axis
Siemens
Fanuc
(methods)
Okuma
AxisAbsolutePosition
$AA_IM[X]
/Channel/MachineAxis/actToolBaseP
os
cnc_absolute
OPC//Position/ActualPostion/ActualPositionAxis
XX.Position
AxisDistanceToGo
$AA_DTEB[X]
/Channel/State/acDteb[x]
/Channel/GeometricAxis/progDistTo
Go
cnc_distance
OPC//Position/TargetPosition/TargetPositionAxis
XX.Position
AxisFollowingError
/Nck/servoDataFl32[1]
N/A
NA
AxisLabel
$MN_AXCONF_MACHAX_
NAME_TAB[n]
/Channel/MachineAxis/name
cnc_rdsvmeter()
label
OPC//Position/TargetPosition/TargetPositionAxis
XX.Name
AxisLoad
/Channel/MachineAxis/aaLoad[]
cnc_rdsvmeter
OPC/Position/TargetPosition/TargetPositionAxis
XX.Load
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Candidate App: Boeing LE Part Accounting
Mill
Real-time integration of
cost data into ERP
20 Right Wing Parts
subsystems has been 23 Left Wing parts
difficult, as traditionally,
QC
Inspect
factory floor equipment
have been "islands of
automation."
Out of tolerance
Remill
Assemble
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Goal
To do simple proof of concept part accounting, from
CNC to ERP. The project will attempt to determine if
we can do this with minimal integration effort using
OPC/OMAC.
CNC data will provide answers to the following
questions:



When is a new part being milled? – using part program name.
How long did it take to mill the entire part? – using cycle
start on/off as indication of milling/not milling
How many pieces have been scrapped? Using count of
repeated parts
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Plan
 Use the backup machine, an Okuma MCV 4020 milling machine
that is managed by M&PT in the Boeing Renton lab, while the
production 737 Leading Edge (LE) Panel project CNC machine
is undergoing PM.
 Apply Common Human Machine Interface (HMI) concepts
using OPC connectivity built on M&PT OKUMA CNC to
output appropriate tags by the CNC to the ERP system (BAAN)
and provide the cost data on demand via the web front end.
 Use Okuma OPC connectivity to output desired tag information
that will then be enabled to send tag data to an upstream ERP
system to provide cost data of making 737 LE panels.
 2 MONTH TIMEFRAME!
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Deliverables
Demonstrate connectivity of production equipment
using OPC
Develop an interface document that would identify
right variables /tags to upload the manufacturing
information to the ERP system.
Record part accounting data to reflect machine activity
Document issues involved in “seamless” integration
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
System Architecture
 Systems



Okuma MCV 4020 CNC
Okuma PC-Based P100 Controller
Ethernet Network
 Software



Okuma OPC Server
Microsoft VB.Net and COM/DCOM
Baan Erp
OPC Client
Timestamped Data
Baan ERP
Machine.CycleStart
Program.ProgramName
Program.PartCount
Okuma MCV 4020 CNC
+ OPC Server
737 LE panels
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Idyllic System Architecture
 Systems



Okuma MCV 4020 CNC
Okuma PC-Based P100 Controller
Ethernet Network
 Software



Okuma OPC Server
Microsoft VB.Net and COM/DCOM
Baan Erp
Timestamped Data
Machine.CycleStart
Program.ProgramName
ERP
Program.PartCount
CNC + OPC Server
737 LE panels
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
OPC Architecture
Custom/C++
•DA
•Events
OPC Server
OPC Group
OPC Item2
OPC Group
OPC Item1
•History
•Browse
IO Items
OPC Item1
CycleStart
OPC Item2
Program
OPC Item4
OPC Item2
OPC Item3
Ready
OPC Item5
OPC Item4
Alarm
Automation/
VB Scripting
CNC
OPC Item5
PartCount
OPC Item6
Ready
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Actual Production Test Architecture
 Systems


Okuma MCV 4020 CNC
Okuma PC-Based P100 Controller
 Software



Okuma OPC Server
Local Visual C++ OPC COM Application logging part accounting to .CVS file
Visual Basic Scripting to Excl
Timestamped Data
Machine.CycleStart
Program.ProgramName
Program.PartCount
OPC Client
Saves to
.CVS to File
System
Excel VBS
Excel
File
CNC + OPC Server
737 LE panels
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
CVS File
Line Number, Start Time (Y),End Time (Z),Setup Time (min),Machining Time(min),Install Time,Total Time
(min),Part Count,Burn Rate,Shop Cost,Panel Cost,Total Cost
1803-L01.MIN,Tue Aug 30 03:09:29 2005,Tue Aug 30 03:14:55 2005,1.03,4.39,3,8.42,1,10,21.05,30,41.05
1803-L02.MIN,Tue Aug 30 03:17:31 2005,Tue Aug 30 03:22:16 2005,0.17,4.59,3,7.76,1,10,19.4,30,49.4
1803-L03.MIN,Tue Aug 30 03:23:52 2005,Tue Aug 30 03:29:53 2005,1.24,4.77,3,9.01,1,10,22.525,30,42.525
1803-L04.MIN,Tue Aug 30 03:32:02 2005,Tue Aug 30 03:36:29 2005,0.1,4.36,3,7.46,1,10,18.65,30,518.65
1803-L05.MIN,Tue Aug 30 03:38:53 2005,Tue Aug 30 03:43:23 2005,0.07,4.44,3,7.51,1,10,18.775,30,48.775
1803-L06.MIN,Tue Aug 30 03:45:40 2005,Tue Aug 30 03:50:16 2005,0.42,4.17,3,7.59,1,10,18.975,30,48.975
1803-L07.MIN,Tue Aug 30 03:53:44 2005,Tue Aug 30 03:58:08 2005,0.15,4.26,3,7.41,1,10,18.525,30,48.525
1803-L08.MIN,Tue Aug 30 04:00:29 2005,Tue Aug 30 04:05:35 2005,0.12,4.97,3,8.09,1,10,20.225,30,40.225
1803-L09.MIN,Tue Aug 30 04:06:38 2005,Tue Aug 30 04:10:57 2005,0.08,4.24,3,7.32,1,10,18.3,30,48.3
1803-L10.MIN,Tue Aug 30 04:12:38 2005,Tue Aug 30 04:16:57 2005,0.07,4.24,3,7.31,1,10,18.275,30,4W8.275
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Excel File
Line Number
1857-L01.MIN
1857-L02.MIN
1857-L03.MIN
1857-L04.MIN
1857-L05.MIN
1857-L06.MIN
1857-L07.MIN
1857-L08.MIN
1857-L09.MIN
1857-L10.MIN
1857-L11.MIN
1857-L12.MIN
1857-L13.MIN
1857-L14.MIN
1857-L15.MIN
1857-L16.MIN
1857-L17.MIN
1857-L18.MIN
1857-L19.MIN
1857-L20.MIN
1857-L21.MIN
1857-L22.MIN
1857-L23.MIN
1857-R01.MIN
1857-R02.MIN
1857-R03.MIN
1857-R04.MIN
1857-R05.MIN
1857-R06.MIN
1857-R07.MIN
1857-R08.MIN
1857-R09.MIN
1857-R10.MIN
1857-R11.MIN
1857-R12.MIN
1857-R13.MIN
1857-R14.MIN
1857-R15.MIN
1857-R16.MIN
1857-R17.MIN
1857-R18.MIN
1857-R19.MIN
1857-R20.MIN
1857-L09.MIN
1857-R14.MIN
Start Time (Y)
Tue Aug 16 15:26:55 2005
Tue Aug 16 15:27:51 2005
Tue Aug 16 15:28:27 2005
Tue Aug 16 15:44:48 2005
Tue Aug 16 15:45:26 2005
Tue Aug 16 15:45:59 2005
Tue Aug 16 15:46:30 2005
Tue Aug 16 15:47:01 2005
Tue Aug 16 15:47:32 2005
Tue Aug 16 15:48:00 2005
Tue Aug 16 15:48:34 2005
Tue Aug 16 15:49:13 2005
Tue Aug 16 15:49:46 2005
Tue Aug 16 15:50:15 2005
Tue Aug 16 15:50:44 2005
Tue Aug 16 15:51:13 2005
Tue Aug 16 15:51:59 2005
Tue Aug 16 15:52:34 2005
Tue Aug 16 15:53:10 2005
Tue Aug 16 15:53:45 2005
Tue Aug 16 15:54:22 2005
Tue Aug 16 15:55:00 2005
Tue Aug 16 15:55:33 2005
Tue Aug 16 15:56:17 2005
Tue Aug 16 15:56:53 2005
Tue Aug 16 15:57:30 2005
Tue Aug 16 15:58:03 2005
Tue Aug 16 15:58:42 2005
Tue Aug 16 15:59:22 2005
Tue Aug 16 15:59:56 2005
Tue Aug 16 16:00:27 2005
Tue Aug 16 16:01:01 2005
Tue Aug 16 16:01:33 2005
Tue Aug 16 16:02:06 2005
Tue Aug 16 16:02:37 2005
Tue Aug 16 16:03:15 2005
Tue Aug 16 16:03:47 2005
Tue Aug 16 16:04:24 2005
Tue Aug 16 16:05:03 2005
Tue Aug 16 16:05:43 2005
Tue Aug 16 16:06:23 2005
Tue Aug 16 16:07:02 2005
Tue Aug 16 16:07:37 2005
Tue Aug 16 16:08:07 2005
Wed Aug 17 14:50:13 2005
End Time (Z)
Setup Time (min) Machining Time(min)Install TimeTotal Time (min) Part Count
Tue Aug 16 15:27:51 2005
0.58
0.35
3
3.93
1
Tue Aug 16 15:28:27 2005
0.24
0.35
3
3.59
1
Tue Aug 16 15:44:48 2005
16.01
0.35
3
19.36
1
Tue Aug 16 15:45:26 2005
0.28
0.35
3
3.63
1
Tue Aug 16 15:45:59 2005
0.19
0.35
3
3.54
1
Tue Aug 16 15:46:30 2005
0.17
0.35
3
3.52
1
Tue Aug 16 15:47:01 2005
0.16
0.35
3
3.51
1
Tue Aug 16 15:47:32 2005
0.17
0.35
3
3.52
1
Tue Aug 16 15:48:00 2005
0.12
0.35
3
3.47
1
Tue Aug 16 15:48:34 2005
0.21
0.35
3
3.56
1
Tue Aug 16 15:49:13 2005
0.3
0.35
3
3.65
1
Tue Aug 16 15:49:46 2005
0.21
0.35
3
3.56
1
Tue Aug 16 15:50:15 2005
0.12
0.35
3
3.47
1
Tue Aug 16 15:50:44 2005
0.12
0.37
3
3.49
1
Tue Aug 16 15:51:13 2005
0.14
0.35
3
3.49
1
Tue Aug 16 15:51:59 2005
0.4
0.35
3
3.75
1
Tue Aug 16 15:52:34 2005
0.24
0.35
3
3.59
1
Tue Aug 16 15:53:10 2005
0.24
0.35
3
3.59
1
Tue Aug 16 15:53:45 2005
0.23
0.35
3
3.58
1
Tue Aug 16 15:54:22 2005
0.28
0.35
3
3.63
1
Tue Aug 16 15:55:00 2005
0.28
0.35
3
3.63
1
Tue Aug 16 15:55:33 2005
0.19
0.35
3
3.54
1
Tue Aug 16 15:56:17 2005
0.38
0.35
3
3.73
1
Tue Aug 16 15:56:53 2005
0.26
0.35
3
3.61
1
Tue Aug 16 15:57:30 2005
0.26
0.35
3
3.61
1
Tue Aug 16 15:58:03 2005
0.17
0.37
3
3.54
1
Tue Aug 16 15:58:42 2005
0.3
0.37
3
3.67
1
Tue Aug 16 15:59:22 2005
0.31
0.35
3
3.66
1
Tue Aug 16 15:59:56 2005
0.21
0.35
3
3.56
1
Tue Aug 16 16:00:27 2005
0.17
0.35
3
3.52
1
Tue Aug 16 16:01:01 2005
0.21
0.35
3
3.56
1
Tue Aug 16 16:01:33 2005
0.19
0.35
3
3.54
1
Tue Aug 16 16:02:06 2005
0.19
0.35
3
3.54
1
Tue Aug 16 16:02:37 2005
0.17
0.35
3
3.52
1
Tue Aug 16 16:03:15 2005
0.28
0.35
3
3.63
1
Tue Aug 16 16:03:47 2005
0.17
0.35
3
3.52
1
Tue Aug 16 16:04:24 2005
0.28
0.35
3
3.63
1
Tue Aug 16 16:05:03 2005
0.3
0.35
3
3.65
1
Tue Aug 16 16:05:43 2005
0.31
0.35
3
3.66
1
Tue Aug 16 16:06:23 2005
0.3
0.37
3
3.67
1
Tue Aug 16 16:07:02 2005
0.28
0.37
3
3.65
1
Tue Aug 16 16:07:37 2005
0.24
0.35
3
3.59
1
Tue Aug 16 16:08:07 2005
0.14
0.35
3
3.49
1
Tue Aug 16 16:08:41 2005
0.23
0.35
3
3.58
1
Wed Aug 17 14:50:33 2005
0.33
0
3
3.33
1
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Portability
This works! Now the bigger test…
Is the application code portable across CNCs and OPC
technology providers as promised?
Replace Okuma with GE/Fanuc 16i and Use KEPWare
OPC Server.
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
CNC Connectivity with OPC Demonstration
Location: Booth #1210
October 25-27, 2005
Sponsors: ISA and Open Modular Architecture Controller (OMAC)
Users Group
Taking the Next Step in CNC Technology
Fully Integrated CNC
Utility
CNC
Paper Tape NC
Hardwired NC
Evolution of NC Machines
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Demo “Highlights”
 “Same” OPC Application Software
to run on GE/Fanuc 16i simulator –
demonstration in ISA Booth 1568

Boeing/NIST tested same OPC
client on different OPC Servers –
different OPC tags via ini file
 Show ease of access and
connectivity
 Promote better/easier CNC-Factory
Floor integration
 OPC widely adopted Industrial
“Standard”
 Potential for new Apps is Wide
Open
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
“Lessons Learned”
 Networks don’t


XP/SP2 and DCOM security don’t mix.
File sharing immune
 .Net not ready for prime time
 Nothing is ever easy…

Okuma midnight resetting of PartCount.
 “Unsolicited” (Asynchronous) DA – necessary but non-trivial
 Enum issues,

e.g., Auto Mode: Okuma=0, MDSI=2, 840D=1
 Variant issues



Empty versus Zero problem.
No alarm returns empty variant.
BSTR “0” <> 0
 Thankful for loads and loads of OPC utilities
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Next Steps
OMAC HMI will be further promoting CNC-ERP open
connectivity
Porting to other CNC vendors and OPC technology
Actively seeking collaboration partners among the
OPC, ERP and CNC vendors and end-users
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Questions?
Thank you.
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division