ppt template -...

WW TSS-19Wonderware MESImplementation and Support Strategies

Presenters:Dan ScottJim Stella

October 2013

@InvensysOpsMgmt / #SoftwareRevolution

/Wonderware

/InvensysVideos

social.invensys.com

© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.

Presenters:Dan ScottJim Stella

October 2013

/Wonderware

/company/Wonderware

Session Agenda

• MES Component Overview

• MES Licensing Options and Features

• Example Customer Scenario

• Preventative Maintenance

• Support Tips

• Upcoming Features

Slide 3

• MES Component Overview

• MES Licensing Options and Features

• Example Customer Scenario

• Preventative Maintenance

• Support Tips

• Upcoming Features

MES ComponentOverview

Slide 4

Wonderware MES Architecture

GalaxyRepository

AOS Platform (M)MES Admin (P)Shop Floor (P)

Operator

InTouch w/.NET Controls

InTouch w/MES API

MES Client

Supervisor

Configurator

ArchestrA IDE

Supervisory (P)

MES Client

Supervisor

ReportsField I/O

ERP DatabaseServer

Supply ChainConnector

Slide 5

DatabaseServer

MiddlewareServer (M,S)

AOS Platform (M)

Key: M = Full Middleware P = Middleware Proxy S = MES Service

App Objectsw/ MES API

OperationsCapability Obj

UtilizationCapability Obj

ReportsServer (M or None)

FactoryConnectorServer (M)

SampleRecording Obj

MES Middleware Host Service

• Connects clients to the database

• Full middleware should be installed on:

• Platforms hosting MES objects

• Manager server

• Terminal servers

• Server running MES Service

• License purchase required per full middleware server (multiple inc.)

• Middleware is not deployed, must be installed manually

• If middleware is remote from database, MES Client must beinstalled

Slide 6

• Connects clients to the database

• Full middleware should be installed on:

• Platforms hosting MES objects

• Manager server

• Terminal servers

• Server running MES Service

• License purchase required per full middleware server (multiple inc.)

• Middleware is not deployed, must be installed manually

• If middleware is remote from database, MES Client must beinstalled

MES Middleware Proxy

• This is the MES Middleware Client component

• All nodes accessing MES middleware require proxy

• Middleware proxy must be installed on IDE node if using EntityModel Builder (EMB)

• You must open/close a capability object editor window before running EMB

• Use Proxy Configuration Editor to test the connection to MW server

• Use MES Client or Configurator to test client connectivity since youwill get better errors

• Proxy is not deployed, must be installed manually

Slide 7

• This is the MES Middleware Client component

• All nodes accessing MES middleware require proxy

• Middleware proxy must be installed on IDE node if using EntityModel Builder (EMB)

• You must open/close a capability object editor window before running EMB

• Use Proxy Configuration Editor to test the connection to MW server

• Use MES Client or Configurator to test client connectivity since youwill get better errors

• Proxy is not deployed, must be installed manually

MES Service

• Only one MES Service can run per database

• Executes minutely, hourly, and daily housekeeping tasks

• Shift changes

• Session clean-up

• Auto-ready jobs

• Run scheduled Supply Chain Connector tasks

• Run scheduled archive and purge tasks

• Generate time-based Quality Samples

Slide 8

• Only one MES Service can run per database

• Executes minutely, hourly, and daily housekeeping tasks

• Shift changes

• Session clean-up

• Auto-ready jobs

• Run scheduled Supply Chain Connector tasks

• Run scheduled archive and purge tasks

• Generate time-based Quality Samples

MES Licensing

Only buy the features you need:

• Operations

• Performance

• Quality

Slide 9

MES Licensing

Work OrderExecution

ProductDefinition

Common

Slide 10

RecordProduction

Reports

MES Licensing

Work OrderExecution

ProductDefinition

ProcedureSteps

DataCollection

Bill ofMaterials

Inventory

Operations

Slide 11

RecordProduction

Reports

ProductSpecifications

ProductionEvents

Tracking

Certifications

LaborManagement

EnterpriseData

Integration

DocumentManagement

MES Licensing

Work OrderExecution

ProductDefinition

OverallEquipment

Effectiveness

EquipmentUtilization &Downtime

Performance

Slide 12

RecordProduction

Reports

MES Licensing

Work OrderExecution

ProductDefinition Quality

Slide 13

RecordProduction

Reports

Sample PlanDefinition

StatisticalProcessControl

QualitySpecifications

Sample PlanExecution

MES Licensing

Work OrderExecution

ProductDefinition

ProcedureSteps

DataCollection

Bill ofMaterials

Inventory

OverallEquipment

Effectiveness

EquipmentUtilization &Downtime

CommonOperations Performance

Quality

Slide 14

RecordProduction

Reports

ProductSpecifications

ProductionEvents

Tracking

Certifications

LaborManagement

Sample PlanDefinition

StatisticalProcessControl

QualitySpecifications

Sample PlanExecution

EnterpriseData

Integration

DocumentManagement

Example Customer

Overview of customer requirements:

Existing App Server and Historian, adding MES

3 production areas: milk, choc milk, strawberry, future drinks

1 central cooler storage

Plan for scaling

Quality requirements for temperature and bacteria incoming

Inventory tracking

ERP used for sales orders, incoming raw material, shipping

Import WOs and inventory from ERP

Final job completed, send inventory to ERP

Slide 15

Overview of customer requirements:

Existing App Server and Historian, adding MES

3 production areas: milk, choc milk, strawberry, future drinks

1 central cooler storage

Plan for scaling

Quality requirements for temperature and bacteria incoming

Inventory tracking

ERP used for sales orders, incoming raw material, shipping

Import WOs and inventory from ERP

Final job completed, send inventory to ERP

Hardware Design Considerations

Current hardware configuration – image

3 platforms to Historian

IO in place

Slide 16

Hardware Design Considerations

New proposed hardware configuration – image

Add dedicated physical MES db/middleware server

Add clients and dedicated MW server for those UI

Slide 17

Software Design Considerations

Add dedicated MES engines for each line w/ full MW on those platforms

The DB server also runs SCC schedules and MES Service

Full MW vs proxy on which nodes

SCC how it runs

OCO/UCO/SRO considerations

Speeds

Multiple job execs

Continuous WO

SQL DB Fill

Slide 18

Add dedicated MES engines for each line w/ full MW on those platforms

The DB server also runs SCC schedules and MES Service

Full MW vs proxy on which nodes

SCC how it runs

OCO/UCO/SRO considerations

Speeds

Multiple job execs

Continuous WO

SQL DB Fill

MES Tips and Common Mistakes:Load ManagementServer / Platform Loading

• What else runs on this node?

• Available system resources?

Engine Loading

• Engine Scan Rate?

– Many capability object functions resultin MES database transactions.

– Consider separate engines for MESobjects versus regular, higher speed,App Objects

Middleware Loading

• Capability Object count?

– No more than 200-300 per platform*

– No more than 50 SROs per platform*

– No more than 30-50 per engine*

– Full middleware on the platformhosting MES App Objects

• Reporting?

Database Loading

• Dedicated MES Database server?

– MES has high transaction count

Slide 19

Server / Platform Loading

• What else runs on this node?

• Available system resources?

Engine Loading

• Engine Scan Rate?

– Many capability object functions resultin MES database transactions.

– Consider separate engines for MESobjects versus regular, higher speed,App Objects

Middleware Loading

• Capability Object count?

– No more than 200-300 per platform*

– No more than 50 SROs per platform*

– No more than 30-50 per engine*

– Full middleware on the platformhosting MES App Objects

• Reporting?

Database Loading

• Dedicated MES Database server?

– MES has high transaction count

*Suggestions dependent on transaction volume and scan rate

MES Tips and Common Mistakes:Maintain Distinct Production Records

• This setting can have a significantimpact on the MES database size

– If enabled (default), a new item_prodrecord is created every time productionis recorded

– If disabled, the system will updateexisting item_prod records

• New feature in 3.5 p02, 4.0 SP2aggregated hourly prod records

Slide 20

• This setting can have a significantimpact on the MES database size

– If enabled (default), a new item_prodrecord is created every time productionis recorded

– If disabled, the system will updateexisting item_prod records

• New feature in 3.5 p02, 4.0 SP2aggregated hourly prod records

MES Tips and Common Mistakes:Multiple Job Execution

• How many Jobs can be runconcurrently on each entity

• More than 10 can cause problems

• OCO has a hard cap of 50, but notrecommended for entities with largetransaction numbers

Slide 21

• How many Jobs can be runconcurrently on each entity

• More than 10 can cause problems

• OCO has a hard cap of 50, but notrecommended for entities with largetransaction numbers

Continuous Work Orders

“But we’re only using Performance, we don’t care about Work Orders”

• The underlying MES database structure and table relationships makesWork Order management important

– Problems with continuously running work orders:

• Database performance degrades over time– Updating database records require the system to query large datasets

• Archiving capabilities are limited (ex: Archive WO where closed > 30 days)

• General recommendation is a new Work Order daily or at shift change

Slide 22

“But we’re only using Performance, we don’t care about Work Orders”

• The underlying MES database structure and table relationships makesWork Order management important

– Problems with continuously running work orders:

• Database performance degrades over time– Updating database records require the system to query large datasets

• Archiving capabilities are limited (ex: Archive WO where closed > 30 days)

• General recommendation is a new Work Order daily or at shift change

MES Tips and Common Mistakes:OCO/UCO Production Counters

Misconfiguration, especially with a rollover counter, can be disastrous

• NEVER set Deadband, Max Value, and Update Interval to 0

– Production may be recorded every engine scan

• Every time production is recorded, you are transacting with the MES Database

– If Maintain Distinct Production Records is enabled (default), you are creating a newitem_prod records every time production is recorded

• UCO rollover counter Max Value MUST be synced with PLC rollover

– OCO rollover counter can be reset on demand, or PLC sync (TN 710)

Slide 23

Misconfiguration, especially with a rollover counter, can be disastrous

• NEVER set Deadband, Max Value, and Update Interval to 0

– Production may be recorded every engine scan

• Every time production is recorded, you are transacting with the MES Database

– If Maintain Distinct Production Records is enabled (default), you are creating a newitem_prod records every time production is recorded

• UCO rollover counter Max Value MUST be synced with PLC rollover

– OCO rollover counter can be reset on demand, or PLC sync (TN 710)

MES Tips and Common Mistakes:Raw Reason Code Management (UCO)

Every Raw Reason Code changeresults in multiple MES Databasetransactions

• Changing reasons too fast can causereason codes to be missed (TN657)

– UCO can only handle current changeplus queue the next change

– Micro stops should be recorded toHistorian (events < 30-60s)*

• Future product plans in theworks to allow for fasterchanges

Slide 24

Every Raw Reason Code changeresults in multiple MES Databasetransactions

• Changing reasons too fast can causereason codes to be missed (TN657)

– UCO can only handle current changeplus queue the next change

– Micro stops should be recorded toHistorian (events < 30-60s)*

• Future product plans in theworks to allow for fasterchanges

*Suggestion dependent on transaction volume and scan rate

Testing of Concept Occurs

• Testing begins on the development environment

• We were trying to use XML files to load Work Orders via SCC, butbegan encountering performance issues

• Implement switch to db import with custom interface tables

• Performance is improved – Why?

• We also realized that report weren’t coming out the way we wanted:Implemented switch from daily WO to shift WO

Slide 25

• Testing begins on the development environment

• We were trying to use XML files to load Work Orders via SCC, butbegan encountering performance issues

• Implement switch to db import with custom interface tables

• Performance is improved – Why?

• We also realized that report weren’t coming out the way we wanted:Implemented switch from daily WO to shift WO

MES Tips and Common Mistakes:Supply Chain Connector

MiddlewareSupply ChainConnector(MES Service)

FileXml or

delimited

Table3rd party orcustom

Slide 26

Supply Chain Connector can have data brought in by either data file ordatabase Table.

Table3rd party orcustom

MES Tips and Common Mistakes:Supply Chain ConnectorQuestions to consider when deciding whether to use files or

tables:

• How much data will I be importing?

• How often will the data be imported?

• How much of the importing data will be new and how much will beupdating existing records?

• What will be creating the new data that will be imported?

Slide 27

Questions to consider when deciding whether to use files ortables:

• How much data will I be importing?

• How often will the data be imported?

• How much of the importing data will be new and how much will beupdating existing records?

• What will be creating the new data that will be imported?

MES Tips and Common Mistakes:Supply Chain ConnectorFile-based imports:

Pros

• Easy to implement

• Good for smaller amounts of data

• Easy one time configuration scenarios

Cons

• Cannot track the processing of individual records

• Higher chances of data integrity issues

• Slower performance with larger amounts of data

Slide 28

File-based imports:

Pros

• Easy to implement

• Good for smaller amounts of data

• Easy one time configuration scenarios

Cons

• Cannot track the processing of individual records

• Higher chances of data integrity issues

• Slower performance with larger amounts of data

MES Tips and Common Mistakes:Supply Chain ConnectorTable-based imports:

Pros

• Able to track and keep information on individual processed records

• Reprocessing of individual records is easier

• Troubleshooting bad records is easier to find.

Cons

• More difficult to implement

• Better for larger amounts of data.

• Needs more maintenance (cleaning out old records, backing up oftables….)

Slide 29

Table-based imports:

Pros

• Able to track and keep information on individual processed records

• Reprocessing of individual records is easier

• Troubleshooting bad records is easier to find.

Cons

• More difficult to implement

• Better for larger amounts of data.

• Needs more maintenance (cleaning out old records, backing up oftables….)

Go Live

Slide 30

Preventative Maintenance

• Database maintenance

– Truncate transaction logs and shrink files and database (TN 664)

– Check fragmentation. Reorganize or rebuild indexes

• Archive and/or Purge

– Large tables:

• item_prod (Production details)

• util_log (Utilization states)

• tpm_stat (OEE stats)

– Custom reports can union data from Prod and Archive databases

• Available from MES Services, not part of the standard product

– Tech Note 746 - Using the New MES 4.0 Archive, Purge and RestoreFunctions

Slide 31

• Database maintenance

– Truncate transaction logs and shrink files and database (TN 664)

– Check fragmentation. Reorganize or rebuild indexes

• Archive and/or Purge

– Large tables:

• item_prod (Production details)

• util_log (Utilization states)

• tpm_stat (OEE stats)

– Custom reports can union data from Prod and Archive databases

• Available from MES Services, not part of the standard product

– Tech Note 746 - Using the New MES 4.0 Archive, Purge and RestoreFunctions

MES Support: Middleware

• Licensing

– MES Licenses must be installed on Middleware servers (restart MW)

– Performance-only or Quality-only license can use OCO for production countsand basic job execution

– MES 4.0 license is valid for MES 4.5

• Database Connection Editor (restart Middleware if changed)

– Verify SQL connectivity

• Middleware Configuration Editor

– Enable XML Trace of all middleware/SP calls with parameters (restart MW)

• Middleware Proxy Configuration Editor

– Test connection to Middleware server

Slide 32

• Licensing

– MES Licenses must be installed on Middleware servers (restart MW)

– Performance-only or Quality-only license can use OCO for production countsand basic job execution

– MES 4.0 license is valid for MES 4.5

• Database Connection Editor (restart Middleware if changed)

– Verify SQL connectivity

• Middleware Configuration Editor

– Enable XML Trace of all middleware/SP calls with parameters (restart MW)

• Middleware Proxy Configuration Editor

– Test connection to Middleware server

MES Support: Error Messages

• MES SMC Log Flags

– UCO – EquipmentStatusRuntime1

– OCO – JobExecutionRuntime1

– SRO – SampleCharacteristicRuntime1

– Entity Model Builder – EntityModelBuilder

– MES Service – FactMES.Server.Services

• MES ArchestrA Objects

– .ErrorMessage attribute

Slide 33

• MES SMC Log Flags

– UCO – EquipmentStatusRuntime1

– OCO – JobExecutionRuntime1

– SRO – SampleCharacteristicRuntime1

– Entity Model Builder – EntityModelBuilder

– MES Service – FactMES.Server.Services

• MES ArchestrA Objects

– .ErrorMessage attribute

MES Troubleshooting:MES Client Debug• Modify C:\Program Files\Wonderware\MES\Client Framework

Modules\aaClient.exe.config

Change this section:



<add name="LogTraceListener“type="System.Diagnostics.TextWriterTraceListener“initializeData="Trace.log" />

Slide 34

• Modify C:\Program Files\Wonderware\MES\Client FrameworkModules\aaClient.exe.config

Change this section:



<add name="LogTraceListener“type="System.Diagnostics.TextWriterTraceListener“initializeData="Trace.log" />

Upcoming New Features

Slide 35

Useful Reference Documents

• MES 4.0 Deployment Guide

• MES 4.0 Development Guide

Slide 36

Useful Tech Notes

• Tech Note 959 – Planning for Supply Chain Connector ImportEfficiency

• Tech Note 753 - Resolving MES Entity Model Builder Errors on aRemote IDE Development Node

• Tech Note 746 - Using the New MES 4.0 Archive, Purge and RestoreFunctions

• Tech Note 744 - Resolving Incorrect Shift Times When MESDB isMoved to Another Time Zone

• Tech Note 723 - Solving Wonderware MES 4.0 Known InstallationIssues

Slide 37

• Tech Note 959 – Planning for Supply Chain Connector ImportEfficiency

• Tech Note 753 - Resolving MES Entity Model Builder Errors on aRemote IDE Development Node

• Tech Note 746 - Using the New MES 4.0 Archive, Purge and RestoreFunctions

• Tech Note 744 - Resolving Incorrect Shift Times When MESDB isMoved to Another Time Zone

• Tech Note 723 - Solving Wonderware MES 4.0 Known InstallationIssues

Useful Tech Notes

• Tech Note 711 – Wonderware MES Operation Capability Object:Configuring Multiple Job Counters

• Tech Note 710 - Wonderware MES Operations Capability Object:Configuring Rolling Counter Reset

• Tech Note 708 - Enabling MES 4.0 Operating System (OS) GroupSecurity

• Tech Note 699 - Wonderware MES Sessn Table and Client Types

• Tech Note 664 - Truncating Operations & Performance TransactionLogs

• Tech Note 657 - Wonderware Performance 3.5 Software:Performance Tips

Slide 38

• Tech Note 711 – Wonderware MES Operation Capability Object:Configuring Multiple Job Counters

• Tech Note 710 - Wonderware MES Operations Capability Object:Configuring Rolling Counter Reset

• Tech Note 708 - Enabling MES 4.0 Operating System (OS) GroupSecurity

• Tech Note 699 - Wonderware MES Sessn Table and Client Types

• Tech Note 664 - Truncating Operations & Performance TransactionLogs

• Tech Note 657 - Wonderware Performance 3.5 Software:Performance Tips

Questions?

Slide 39

THANK YOU