Factors determining the optimal architecture of a manufacturing execution system utilised in automated production. By David Lee, BSc (Honours) Waterford Institute of Technology INSTITIÚID TEICNEOLAÍOCHTA PHORT LÁIRGE A Thesis Submitted in Fulfilment of the Requirements for the Degree of Master of Science Research Supervisor Research Supervisor Dr. Noreen Quinn-Whelton Michael McCarthy Submitted to Waterford Institute of Technology March 2013 David Lee MSc. Thesis Waterford Institute of Technology INSTITIÚID TEICNEOLAÍOCHTA PHORT LÁIRGE Declaration: I declare that the writing of this thesis and the research contained within is my own work. Any assistance received has been acknowledged where appropriate. Signed: David Lee Date: Page 2 of 232 David Lee MSc. Thesis Abstract Information Technology driven manufacturing has progressively evolved since the first introduction of computer systems. As the needs of industry become more demanding, the software used to drive manufacturing must continually advance. In order to remain competitive, businesses need to keep their costs of production down, maintain high product quality and also drive maximum efficiencies. Only through automated manufacturing processes, are businesses able to achieve these goals. High levels of automation require the implementation of sophisticated Manufacturing Execution Systems (MES). This research investigates the optimal design elements for MES, with particular focus on the potential for a web based architecture. Product comparisons, technological investigations and surveys were employed to elucidate MES design and potential areas of enhancement. It was found that while a web based MES could out-perform the traditional client-server model on various aspects, there are too many security concerns to be viable as a cloud hosted application. Page 3 of 232 David Lee MSc. Thesis Acknowledgements Thanks to Michael and Noreen for all their assistance. Without the backing of Bausch + Lomb this research would not have been possible. Page 4 of 232 David Lee MSc. Thesis Glossary Some acronyms in the glossary have not been elaborated in first appearance of text due to them being synonymous with usage, giving diminished significance to their unabbreviated text. Also a small number of acronyms used in the text are not listed here because they have been mentioned for completeness but have no major relevancy to this research. Acronym Meaning ActiveX Framework for defining reusable software components AI Artificial Intelligence AJAX Asynchronous JavaScript And XML API Application Program Interface ASCII American Standard Code for Information Interchange ASP Application Service Provider BAM Business Activity Monitoring BI Business Intelligence BOM Bill Of Materials BPM Business Process Management CAMS MES utilised in Bausch + Lomb CAPA Corrective And Preventative Action CDN Content Delivery Network CGI Common Gateway Interface CIM Computer Integrated Manufacturing COM Common Object Model COTS Common Off The Shelf CPU Central Processing Unit CRM Customer Relationship Management CSPRNG Cryptographically Secure Pseudo Random Number Generator CSRF Cross-site request forgery CSS Cascading Style Sheets CSV Comma Separated Values DAML DARPA Agent Markup Language DEP Data Execution Protection DHR Device History Record DLL Dynamic Link Library Page 5 of 232 David Lee MSc. Thesis DHTML Dynamic Hyper Text Markup Language DNS Domain Naming System DOM Document Object Model DOS Denial Of Service eDHR electronic Device History Record EDI Electronic Data Interchange ERP Enterprise Resource Planning FDA Food and Drug Administration Frames HTML technique for displaying several Web pages in the same browser window GUI Graphical User Interface GUID Globally Unique Identifier GZIP Open source command line data stream compressor and archiver HCI Human Computer Interaction HTML Hyper Text Markup Language HTTP Hyper Text Transfer Protocol IDS Intrusion Detection System IE Microsoft Internet Explorer iFrames HTML technique for placing a window within a window in same browser window IIS Microsoft Internet Information Services IT Information Technology JavaScript Scripting language supported by all mainstream browsers JIT Just In Time JSON JavaScript Object Notation KPI Key Performance Indicator LAN Local Area Network LIMS Learning Information Management System Mashup Web page that aggregates content from different sources MDAC Microsoft Data Access Component MES Manufacturing Execution Systems MIM Man In the Middle MRP Materials Requirement Planning MVC Model View Controller NPI New Product Introduction Page 6 of 232 David Lee MSc. Thesis ODBC Open Database Connectivity OEE Overall Equipment Effectiveness OLAP OnLine Analytical Processing OPC OLE for Process Control OS Operating System OWL Web Ontology Language P2P Peer to Peer PC Personal Computer PDA Personal Digital Assistant PERL Practical Extraction and Report Language PLC Programmable Logic Controller PRNG Pseudo Random Number Generator RAC Real Application Cluster RAD Rapid Application Development RDF Resource Description Framework REST REpresentational State Transfer RFC Request for Comment RFID Radio-frequency identification ROI Return On Investment RS232 Standard for communication to devices through serial ports RSS Really Simple Syndication RXTX Java framework for communication to devices via RS232 SAN Storage Area Network SCADA Supervisory Control And Data Acquisition SDLC Software Development Life Cycle SFIS Shop Floor Information System SIP Session Initiation Protocol SOA Service Orientated Architecture SOAP Simple Object Access Protocol SOX Sarbanes OXley SPARQL RDF query language SPC Statistical Process Control SQL Structured Query Language SSI Server Side Includes SVG Scalable Vector Graphics Page 7 of 232 David Lee MSc. Thesis UML Unified Modelling Language UNC Universal Naming Convention URL Uniform Resource Locator VBScript VB Scripting language used for Internet Explorer browser and windows platforms. VPN Virtual Private Network W3C World Wide Web Consortium WaSP Web Standards Project WIP Work In Progress WSDL Web Services Description Language WWW World Wide Web XHTML eXtensible HyperText Markup Language XLink XML Linking Language XML Extensible Markup Language XPointer XML Pointer Language XSL eXtensible Stylesheet Language XSLT eXtensible Stylesheet Transformation Language XSS Cross-site scripting Page 8 of 232 David Lee MSc. Thesis Table of Contents: 1 INTRODUCTION .............................................................................................. 16 1.1 DEFINITION OF MES ..................................................................................... 16 1.2 RESEARCH QUESTIONS ................................................................................. 18 1.3 JUSTIFICATION .............................................................................................. 18 1.4 SCOPE LIMITATIONS ...................................................................................... 19 1.5 OUTLINE OF THESIS ....................................................................................... 20 2 METHODOLOGY ............................................................................................ 23 2.1 HYPOTHESES ................................................................................................. 24 2.2 COMPARATIVE ANALYSIS OF COTS MES ..................................................... 25 2.3 GOVERNANCE OF MES DESIGN THROUGH INDUSTRY STANDARDS AND REGULATION ............................................................................................................. 25 2.4 UTILIZATION OF WEB BASED SURVEY FOR IN -DEPTH MES ANALYSIS ........... 26 2.5 CONCLUSION ................................................................................................. 30 3 LITERATURE REVIEW ................................................................................. 31 3.1 INTRODUCTION ............................................................................................. 31 3.2 THE HISTORY AND ADVANCES OF MANUFACTURING ..................................... 32 3.3 MACRO -ECONOMIC ASPECTS OF AUTOMATION .............................................. 34 3.4 CONTEMPORARY MES DESIGN PRINCIPALS .................................................. 36 3.5 EMERGENT MES TRENDS .............................................................................. 37 3.6 PROBLEMS ASSOCIATED WITH DESKTOP SOFTWARE ...................................... 38 3.7 BENEFITS OF WEB BASED MANUFACTURING SYSTEMS ................................ 41 3.8 WEB BASED DEVICE COMMUNICATION .......................................................... 43 3.9 REUSABLE MODELS FOR OPTIMAL SOFTWARE DESIGN ................................... 48 3.10 MES USABILITY ........................................................................................... 53 3.11 UTILIZING TOUCH SCREENS IN A MANUFACTURING ENVIRONMENT ............... 63 3.12 MES SECURITY ............................................................................................. 64 3.13 SYSTEM ERRORS AND FAILURE MODES ........................................................ 66 3.14 REVIEW OF OTHER MES APPLICATIONS ....................................................... 73 3.15 LITERATURE REVIEW CONCLUSIONS ............................................................ 78 4 WEB SOFTWARE FUNCTIONALITY ......................................................... 82 Page 9 of 232 David Lee MSc. Thesis 4.1 WORLD WIDE WEB CONSORTIUM ...............................................................