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MacLean-­Fogg Uses  
IIoT to  Gain  Industry  
Advantage
Chris  Misztur
Scott  Masker
with Tony  Paine
Agenda
• Company  overview
• Industry  4.0  meaning
• Opportunities
• Change  model
• Global  architecture
• How  to  start
Company  Overview
• Private  enterprise
• 3000  employees
• 34  locations
• $1bn+  sales
• 100+  patents
• Electric  utility
• Telecommunications
• Civil  markets
• Fastener  components  
• Engineered  components
• Engineered  plastics
• Linkage  and  suspension  components
• Investments
• Private  equity  holdings
Industry  4.0  Meaning
• Established  2010
• Internal  lean  manufacturing  training
• Employee  empowerment
• Operator  =  doing  +  thinking
• Executive  backed
operational  
transformation
information
technology
• ERP  implementation
• Not  only  a  support  department
• Value  add  opportunities
• Innovation
• Waste  elimination
• Process  stability
joint  effort
Opportunities
• Operational  unknowns
• Machine  efficiency
• Defect  rates
• Machine  downtimes
• Excess  inventory
• Quality  problems
• Long  lead  times
$$$
• Non-­value  added  activities
• Weighing  product
• Piece  reporting
• Inspection  &  rework
Change  Model
business  needs
software hardware
.
visualization  of  accurate
real-­time  information
The  Way  Forward
.
Change  Model
assets PLC Kepware BizTalk JD  Edwards
• Started  at  1st process
• Already  had  PLC
• Internal  counters
Kepware BizTalk JD  EdwardsPLCassets
Change  Model
.
Serial  Devices
• Less  than  50%  equipment  
connected
• Some  equipment  serial  
connected  via  outdated  
legacy  drivers  and  
software
• Start  looking  at  lower  cost  
alternatives  to  PLCs
Kepware BizTalk JD  EdwardsPLCassets
Change  Model
.
Kepware BizTalk JD  EdwardsPLCassets
Change  Model
Kepware
• Hub  for  real-­time  machine  communication
• Standardizes PLC  wire  protocols  to  OPC-­UA
• Bridges  shop  floor  and  data  center
IOT  agents
MQTT HTTP
• publish-­subscribe
• lightweight
• portable
• topic  based
• Facebook
• REST  API
• request-­response
• read  and  write
• Internet  standard
BizTalk JD  EdwardsPLCassets
How  to  get  the  data  out?
OPC-­UA
DATABASE
SPLUNK
Change  Model
• Topic  kepserver/0200/forming/1696
{
"timestamp":1443294150155,
"values":[
{"id":"0200_Forming.1696.GoodPieces","v":"1389","q":true,"t":1443294140795},
{"id":"0200_Forming.1696.DefectivePieces","v":"0","q":true,"t":1443294140795},
{"id":"0200_Forming.1696.AssetNumber","v":"1696-­1200","q":true,"t":1443294140795},
{"id":"0200_Forming.1696.WorkOrderNumber","v":"92800-­000","q":true,"t":1443294140795},
{"id":"0200_Forming.1696.WorkOrderOperationSequence","v":"11","q":true,"t":1443294140795},
{"id":"0200_Forming.1696.EmployeeNumber","v":"64500","q":true,"t":1443294140795}
]
}
Kepware BizTalk JD  EdwardsPLCassets
• Earlier  models
• Topic  per  data  point  (client  blocking)
• Publish  only  changed  data  (chatty)
division department asset
Change  Model
BizTalk JD  EdwardsPLCassets Kepware
Change  Model
Apache  
ActiveMQ
Kepware
JSON
kepserver/0200/forming/1696
MQTT  publish
JMS  API  subscribe
IOT
Gateway
kepserver.*
• process
• store/forward
• analyze
Change  Model
BizTalk JD  EdwardsPLCassets Kepware
• XML  messaging  platform
• Microsoft  SQL  backed
• Receive  and  send  ports
• Orchestrations  
• XLANG/s  BPEL
• Messaging  language
• C#  expression
ü File
ü FTP  (FTPS)
ü HTTP(s)
ü MSMQ
ü POP3
ü SFTP
ü SMTP
ü SOAP
ü WCF
ü SB-­Messaging
ü MQSeries
ü SharePoint
ü TCP-­IP  Socket
ü Oracle
ü SAP
ü PeopleSoft
ü JD  Edwards
ü LDAP
ü JMS
ü RSS
ü SSH
ü AMQP
ü XMPP
ü Salesforce
ü Dynamics  CRM
ü Google
ü Twitter
ü Facebook
ü Fax
ü PowerShell
ü ZeroMQ
Change  Model
BizTalk JD  EdwardsPLCassets Kepware
(typical  development  scenario)
change  model
BizTalk JD  EdwardsPLCassets Kepware
kepserver.*
JSON XMLreceive  pipeline
receive
port
processing  
orchestration  BPEL
JMS
send
ports
JDE REPORT  PIECES
COMPLETED
SQL
UPDATE  ASSET  OEE
JMS
ASSET  ACTIVITY
cm
(ALTERNATIVE)
Enterprise  System
With  All  Needed  Modules
Change  Model
BizTalk JD  EdwardsPLCassets Kepware
.
Finance
Asset  Management
Order  Management
Reporting
Mobility
Production
Open  architecture  allowing  for  customization
Change  Model
BizTalk JD  EdwardsPLCassets Kepware
.
BizTalk
JDE
Custom
Function
Interoperability
Table
Backflush
Function
Small  Data  Set  
[WO  User
Quantity  ] Enterprise  
Data
Completion
Message
JDE
Custom
Function
BizTalk
Completion  OK
Or
Errors  Reported
Global  Architecture
Kepware
Kepware
factory  A
factory  Z
ActiveMQ
BizTalk
JD  Edwards
data  center
How  to  Start
• Start  where  you  know
• “Borrow”  hardware  from  
your  controls  engineer
• Write  some  MQTT  code
• Become  familiar  with  
message  brokers
How  to  Start
BizTalk JD  EdwardsPLCassets Kepware
• You’re  not  a  Microsoft  shop?
• My  personal  rapid  prototyping  platform
• Open  source
• Document  store
• XQuery  (XML,JSON,Unstructured)
• JMS  API  support
• JAVA  plug-­ins
• Web  server
• REST  API
Questions?
Kepware
BizTalkJD  Edwards
ActiveMQ
vendor  specific
MQTT
Payload  containing  work-­order,  employee,  and  piece  information
JMS
Call  business  function
Run  Backflush
Process
Business  function  response
Thank  You
cmisztur@macleanfogg.com
smasker@macleanfogg.com
sensing
interconnected
intelligent

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Smart Industry 2015: MacLean-Fogg Uses IIOT To Gain Industry Advantage

Editor's Notes

  1. Many Assets To Choose From Decided on Former PLC already connected Could remove step of scale weighting