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WW OPS-11

Wonderware Workflow:A Plant Engineer's Perspective

Roger SmithWonderware Solutions Architect

@InvensysOpsMgmt / #SoftwareRevolution

/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.

Roger SmithWonderware Solutions Architect /Wonderware

/company/Wonderware

Session Topics & Objectives

Challenges for Enterprise & Industry

Opportunity & Objectives for Remedy

Workflow & Business Process Management

Applying Wonderware Workflow to the Industrial Space

Building on Wonderware System Platform Infrastructure

Examples of Wonderware Workflow in Action

Slide 3

Challenges for Enterprise & Industry

Opportunity & Objectives for Remedy

Workflow & Business Process Management

Applying Wonderware Workflow to the Industrial Space

Building on Wonderware System Platform Infrastructure

Examples of Wonderware Workflow in Action

Real-World Challenges…

Many Data Sources:• ERP

– Orders/Finished Goods

– Raw Materials

• Quality/LIMS

• Ops Management– Process Specifications

– Consume/Produce/WIP

– Asset Performance/OEE

– Historian

• Maintenance EAM/CMMS

Many Roles:• Operations

• Maintenance

• Quality

• Safety

• Environmental

• Supply Chain

• Finance

• Corporate

Many Systems:• Enterprise Applications

– ERP, EAM/CMMS, Custom DB

• Automation Applications– PLC, DCS, HMI, SCADA, MES

• Desktop Applications– Word, Excel, Outlook, Visio

• Web-Based– Custom Portal, SharePoint

• Manual – Human Decision– Voice, Text, Email

Slide 4



– Raw Materials

• Quality/LIMS




– Historian



• Maintenance

• Quality

• Safety

• Environmental

• Supply Chain

• Finance

• Corporate






• Manual – Human Decision– Voice, Text, Email

Collaborative Objective:High Performance

Slide 5

The BIGGER Challenge –System to People Collaboration

System

ManualProcess

AutomatedProcess

Slide 6

System

System

ManualProcess

ManualProcess

AutomatedProcess

Collaborative Reality Feels Like This…

Slide 7

Real-World Example:Modeling & Mapping Complex Activities

Slide 8

Challenges Unique to Industry

• Automation systems not connected to othersystems in real-time.

• Automation & Information Systems aren’ttightly and methodically connected to humanaction/reaction.

• Results negatively impact the business:

−Automated processes become semi-manual.

−Operation is inconsistent or untimely.

−Records of action lacking or non-existent.

Slide 9

• Automation systems not connected to othersystems in real-time.

• Automation & Information Systems aren’ttightly and methodically connected to humanaction/reaction.

• Results negatively impact the business:

−Automated processes become semi-manual.

−Operation is inconsistent or untimely.

−Records of action lacking or non-existent.

Industrial Challenges:OperationsHuman activities surrounding the process:

– Machine setup, process changeover.

– Manual operation of peripheral components.

– Change in upstream/downstream process.

Unexpected or unpredictable operation:

– Events: Equipment failure, materials outage, waste, spill, emissions

– Cost Variance: Excessive time, energy, labor, materials, rework

Response to alarms detected by Automation System:

– High level, low temperature, no output.

– Safety systems, interlocks, guard systems.

Slide 10

Human activities surrounding the process:

– Machine setup, process changeover.

– Manual operation of peripheral components.

– Change in upstream/downstream process.

Unexpected or unpredictable operation:

– Events: Equipment failure, materials outage, waste, spill, emissions

– Cost Variance: Excessive time, energy, labor, materials, rework

Response to alarms detected by Automation System:

– High level, low temperature, no output.

– Safety systems, interlocks, guard systems.

Industrial Challenges:Post-Activity InformationInformation captured with process context:

– Time-series process data

– Alarm & Event History

– Utilization/OEE

– Energy Consumption & Intensity

– Genealogy/Traceability

– Asset Health & Runtime Information

– Data Analysis & Dashboards

None of the above report systems “do something”.

Slide 11

Information captured with process context:

– Time-series process data

– Alarm & Event History

– Utilization/OEE

– Energy Consumption & Intensity

– Genealogy/Traceability

– Asset Health & Runtime Information

– Data Analysis & Dashboards

None of the above report systems “do something”.

Inevitability: The Auditors Cometh…

Internal Audits

• Operation, Quality, Safety, Training

• Materials, Maintenance, Spare Parts

External Audits

• Environmental

• Safety (People, Product, Community)

• Legal/Financial

Auditors ask three key questions:

1. “Do you have a procedure for that?”

2. “Are you following your procedure?”

3. “Can you prove it?”

Slide 12

Internal Audits

• Operation, Quality, Safety, Training

• Materials, Maintenance, Spare Parts

External Audits

• Environmental

• Safety (People, Product, Community)

• Legal/Financial

Auditors ask three key questions:

1. “Do you have a procedure for that?”

2. “Are you following your procedure?”

3. “Can you prove it?”

Solution: Workflow

ModelModel the Process – Create Processes, Forms, & Reports

ExecuteExecute the Process – Manage & Escalate Tasks, Coordinate Resources

AnalyzeAnalyze the Process - Find Bottlenecks, Get Alerts

ImproveImprove the Process – Continuous Improvement

Slide 13

ModelModel the Process – Create Processes, Forms, & Reports

ExecuteExecute the Process – Manage & Escalate Tasks, Coordinate Resources

AnalyzeAnalyze the Process - Find Bottlenecks, Get Alerts

ImproveImprove the Process – Continuous Improvement

Workflow: Criteria for Success

Access to the Right Information:

• Accurate

• Timely

• In Context to the Process

Take the Right Action at the Right Time:

• People

• Procedures

• Systems

– Process

– Plant

– Business

Slide 14

Access to the Right Information:

• Accurate

• Timely

• In Context to the Process

Take the Right Action at the Right Time:

• People

• Procedures

• Systems

– Process

– Plant

– Business

Complex Workflows• Transitions

– Inhibits the execution of a workflow until acondition is met

• Conditional Branching– Allows one branch of activities to execute

based on the evaluation of an expression

• Decision Branch– Executes one branch of activities if the

evaluation of an expression is true. Executesthe alternate branch if the evaluation is false.

• Loop– Executes a series of activities until a condition

is met.

• Queuing– Manages tasks efficiently

WF Trigger - Start

Look Up Product Codefrom Lot ID

Wait for CNC ProgramTo be downloaded

Standard SetupProcedure Verification

Verify ConsumablesAgainst BOM

CorrectConsumable

Materials

Wait fordownload to complete

Slide 15

• Transitions– Inhibits the execution of a workflow until a

condition is met

• Conditional Branching– Allows one branch of activities to execute

based on the evaluation of an expression

• Decision Branch– Executes one branch of activities if the

evaluation of an expression is true. Executesthe alternate branch if the evaluation is false.

• Loop– Executes a series of activities until a condition

is met.

• Queuing– Manages tasks efficiently

Issue the “START”Transaction

END

ConsumablesCorrect?

CorrectConsumable

Materials

NO

YES

SystemPlatform

Control/SCADA

Workflow Platform

Solution Focus

• One Window

• Intuitive Forms

• Human Workflows

• 100% browser based

• Integration withexisting applications

WonderwareWorkflow

SAP

IntelaTracMobile

Solutions

MicrosoftBizTalk

MicrosoftSharePoint2007/2010

InTouchHMI

Types of Workflows

• Application Specific

• Workflow PlatformSafety

MES

“Every Stakeholder thatneeds to be involved,gets involved”

Slide 16

Solution Focus

• One Window

• Intuitive Forms

• Human Workflows

• 100% browser based

• Integration withexisting applications

WonderwareWorkflow

IntelaTracMobile

Solutions

Model-basedTechnology

3rd PartyApplications

MicrosoftOffice

MicrosoftBizTalk

Outlook

Word

LIMSPLM

ROMeo

PIPEPHASE

OTS

“Every Stakeholder thatneeds to be involved,gets involved”

How Can We Do That?

Slide 17

Wonderware System Platform is:Collection of software components that provides:• Data Acquisition, contextualization, and aggregation

• Supervisory Control

• Historization

• Visualization & Annunciation

• Reporting

• Unified Development Environment

• Extensible Container for Advanced Applications

Collection of software components that provides:• Data Acquisition, contextualization, and aggregation

• Supervisory Control

• Historization

• Visualization & Annunciation

• Reporting

• Unified Development Environment

• Extensible Container for Advanced Applications

Wonderware System Platform:Core Component Overview

Wonderware System Platform

Wonderware ClientsHistorian Client(Analysis Client)

Historian Client(Analysis Client)

Information Server(Web Reporting Client)Information Server

(Web Reporting Client)InTouch

(Visualization)InTouch

(Visualization)

Slide 19

Wonderware System Platform

Application ServerApplication Server HistorianHistorianInformation

ServerInformation

Server

Device Integration ProductsDevice Integration Products

3rd PartyData

Sources

3rd PartyData

SourcesSoftware

ApplicationsSoftware

Applications3rd Party

Controllers3rd Party

Controllers

One Platform for Enterprise Control

Supervisory Control

Enterprise Service BusEnterprise Service Bus

Business Transactions

Functions

Historian

SupervisoryControl

Application Models

- Plant Model

- Templates

- Standards

- Operations

- Security

- Intelligence

Common Services

- Global Naming

- Security

- Manage/Deploy

- Messaging

- Alarm\Events

- High Availability

PresentationHMI

Web ProductionMES

PerformanceOEE

Enterprise Integration

Device Integration Service BusDevice Integration Service Bus

Time Series Data

Field Devices

System PlatformSystem PlatformHistorian

Application Models

- Plant Model

- Templates

- Standards

- Operations

- Security

- Intelligence

Common Services

- Global Naming

- Security

- Manage/Deploy

- Messaging

- Alarm\Events

- High Availability

Web

Device Integration

Analyze

Report

ProductionMES

MaintenanceCBM

Energy MgmtCEM

WorkflowBPM

IntelligenceEMI

Wonderware Workflow Components

Wonderware Workflow Software

EnterpriseConsole

BizTalkConnector

SharePointConnectorSharePointConnector

SystemPlatform

Connector

SystemPlatform

Connector

IntelaTracConnector

InformationServer

Connector

InformationServer

Connector

Slide 21

BAM Reports

FormDesigner

ProcessDesigner

BizTalkConnector

BizTalkConnector

SharePointConnector

SAPConnector

SAPConnector

SystemPlatform

Connector

MESConnector

MESConnector

IntelaTracConnectorIntelaTracConnector

HistorianConnectorHistorianConnector

InformationServer

Connector

InformationServer

Connector

OPC UAClient

Connector

OPC UAClient

Connector

System Platform ConnectorComponentsAutomation Object

• $WorkflowGateway Object

Script Function Library

• Workflow Toolbox

• Workflows Tab

.NET Controls

• BAM

• Fill Form

• Inbox

• List Form

• List View

• Workflow Status

Slide 22

Automation Object

• $WorkflowGateway Object

Script Function Library

• Workflow Toolbox

• Workflows Tab

.NET Controls

• BAM

• Fill Form

• Inbox

• List Form

• List View

• Workflow Status

IDE: Workflow Object Integration

Deploy New or Modified Workflow

Slide 24

After the barrel falls off…

… What happens next?

Example: Hazardous Spill Response

Issue Identified byConveyor Monitoring system

Kevin opens his inbox andfills the form with relevantinformation and submits

the form . (System ensuresinformation is complete)

Did Kevintake action?

Workflow is triggered

Yes No

No

SupervisorApprovalreceived

Supervisor is notified toreview the form submittedby Kevin and approve as

appropriate

InTouch Screen(Action Needed)

Slide 29

Escalation sent to Kevinand Supervisor is Alerted

Workflow Ends

Yes

App Server updated withcontextual information and

Documents are posted to complyto legal regulations

App Server updated withcontextual information and

Documents are posted to complyto legal regulations

Yes

SupervisorApprovalreceived

Supervisor is notified toreview the form submittedby Kevin and approve as

appropriate

Workflow Runtime Execution

Slide 30

Example: Lockout / Tagout Process

LockoutTag

Required

Yes

No

Notification to affectedemployees indicating

maintenance.

Visible in SC

AD

A display

Issue Identified byControl System

or Operator

Notify Maintenance /Servicing Crew

Slide 35

Completed notificationsent to supervisor and

affected employees

Machine Shutdownand lockout tags

implemented

Restore MachineTag update

Visible in SC

AD

A display

Perform Maintenance

WorkflowEnds

Example: Energy Peak Demand Avoidance

Monitor the Real-time DemandDetect impending deviation

Notifications are sent tothose who will be impactedby a load shedding event.

Kevin has to explicitlyauthorize halting further

production to avoiddemand charges

Did Kevintake

action?

Workflow is triggered

Yes NoLead Ackreceived

Production Leads arenotified to not start neworders and put current

orders on hold

Supervisor Screen(Action Needed)

Slide 36

Escalation sent toPlant Manager

HR Alerted

Workflow Ends

Yes

Audit trail is updated with allactions and a snapshot of current

energy demand is captured.

Audit trail is updated with allactions and a snapshot of current

energy demand is captured.

Yes

Lead Ackreceived

Production Leads arenotified to not start neworders and put current

orders on hold

Online MonitoringSystem

SCADA detects‘Main Break’

No

Close Valve forFaulty Line

Activate alternateflow

Notify Lab Personnel

Notify PolicePersonnel

Notify UtilityMaintenance Crew

Collaborationwith Lab

Check forcontamination

YesCompare withthe permissible

standards

Normal

Complex Example: Pipeline Break

Slide 37

Implement ‘Boil Water’Ordinance

FlushPipeline

Initiate ConsequenceManagement Plan

Lift the ordinance

Yes

No

Repair pipeline



YesCompare withthe permissible

standards

High

Normal

High

Normal

Compare withthe permissible

standards

Workflow Process Designer & Activities

Slide 38

Workflow Activities

Slide 39

Beyond Automation:Workflow Examples

• Energy: Peak/Demand Response

• Quality: HACCP, Recall, Sampling/Testing

• Safety: LOTO, Hot Work Permit, Confined Space Entry

• Operations: Training, Execution, Exceptions, Alarms, Cleaning

• Maintenance: Shutdown, Repair/Replace, Startup, Auto W.O.

• Engineering: Plant Shutdown/Startup, Critical Asset Procedures

• R&D: New Product Development & Testing

• Supply Chain: Inventory Reconciliation, Materials Staging

Slide 40

• Energy: Peak/Demand Response

• Quality: HACCP, Recall, Sampling/Testing

• Safety: LOTO, Hot Work Permit, Confined Space Entry

• Operations: Training, Execution, Exceptions, Alarms, Cleaning

• Maintenance: Shutdown, Repair/Replace, Startup, Auto W.O.

• Engineering: Plant Shutdown/Startup, Critical Asset Procedures

• R&D: New Product Development & Testing

• Supply Chain: Inventory Reconciliation, Materials Staging

Real-World ChallengesReal-World Opportunity!



– Raw Materials

• Quality/LIMS




– Historian



• Maintenance

• Quality

• Safety

• Environmental

• Supply Chain

• Finance

• Corporate






• Manual – HumanDecision– Voice, Text, Email

Slide 41



– Raw Materials

• Quality/LIMS




– Historian



• Maintenance

• Quality

• Safety

• Environmental

• Supply Chain

• Finance

• Corporate






• Manual – HumanDecision– Voice, Text, Email

Highlights: Wonderware Workflow 2012

Business Value

• Enable Operational Improvements

• Improve Procedural Quality, Consistency

• Adhere to and enforce Regulatory Compliance

Key Capabilities

• Digitally Capture, Institutionalize BestPractices

• Preconfigured Workflows

• Business to Mfg. Connectivity(human-centered)

Slide 42

Business Value

• Enable Operational Improvements

• Improve Procedural Quality, Consistency

• Adhere to and enforce Regulatory Compliance

Key Capabilities

• Digitally Capture, Institutionalize BestPractices

• Preconfigured Workflows

• Business to Mfg. Connectivity(human-centered)

Architecture / Topology

Workflow EngineTask Scheduler

Communication Service



Central Configuration Site locationEnterprise Console informationGlobal configuration settings

Central Configuration Site locationEnterprise Console informationGlobal configuration settings Repositories

Central Configuration SiteEnterprise Console


SkeltaServer 1

SkeltaServer n

SkeltaFarm DB

SkeltaClient 1

SkeltaClient n

SkeltaDatasource 1

SkeltaDatasource n

Slide 44





Central Configuration Site locationEnterprise Console informationGlobal configuration settings

Central Configuration Site locationEnterprise Console informationGlobal configuration settings RepositoriesRepositories



Farm DBFarm DB

Datasource 1Datasource 1 Datasource nDatasource n

Repository 1 Repository n

Wonderware Workflow SoftwareSkelta BPM.NET ArchitectureSkelta Server Controls can be reused and embeddedin a custom ASP.NET application. These same controlsare used in Skelta Enterprise Console, the ArchestrAIDE and ArchestrA Graphics.

Skelta Enterprise Console is a web-based interfacethat allows authorized users to build workflow drivenapplications and also allows users to participate inthese applications.Skelta Repository contains workflow definitions,

queues, calendars, settings, workflow execution dataand Business Activity Monitoring (BAM) data.

Forms Engine is responsible for every activity starting fromthe time a form is opened till a form is closed. It captures all thereal-time user inputs, processes the inputs and displays thisinformation in terms of controls, business logic and usability.

The Integration Layer acts as aninterface between Skelta BPM.NETand third-party applications.

Supports the following Security &Directory Services:1.) Active Directory2.) Lightweight Directory Access

Protocol (LDAP)4.) Any User Directory5.) .NET Role Provider6.) ArchestrA Security

Delivery Channels are interfaces for users to interact withworkflows. Skelta BPM.NET provides multiple deliverychannels which include: Browser, Messenger Services, MobilePhones, Email, MS Outlook, Desktop Applications.

The Skelta Services comprise: Workflow Engine Services,Task Scheduler Services, Skelta Communication Services,Skelta Advanced Server Service.

Web Services - Skelta BPM.NETprovides out-of-the-box activities thatcan be used to call a third-party WebService from a workflow.

Skelta Object Access allows reuse of third-party .NET objects. Allows registration ofthird-party object assemblies.

The Enterprise Event Bus handles third-partyevents that trigger a workflows. The third-partyevents can include updating SharePoint lists,updating files and receiving e-mails.

Microsoft Integration - SkeltaBPM.NET integrates with thefollowing Microsoft applications:1.) Exchange2.) SharePoint3.) Word4.) InfoPath5.) SQL6.) BizTalk7.) Visio