rfid -enabled automation in support of factory integration€¦ · typical example: dod logistics...

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RFIDRFID--enabled Automation in enabled Automation in

Support of Factory Support of Factory

IntegrationIntegration

Robin Qiu, Ph.D.

Penn State, USAEmail: [email protected]

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ControlGen’s Real Time Visibility Solution

http://www.controlgen.com

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Point-of-care Service Scenarios

Service-oriented Community/Society

Google?, or Yahoo!?

• Fast (real time)

• Accurate• Easy to use• Cheap

(Standard)

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Google?, Google?,

Yahoo!?, Yahoo!?,

Or ?Or ?

• Fast (real time)

• Accurate• Easy to use• Cheap

(Standard)

Point-of-need Service Scenarios

SS1: a traveler

needs assistance.

SS2: an overturned truck loaded

with hazardous chemicals.

SS3: a truck loaded

with commodity that

needs specific attention.


“A crisis management team responds to a chemical spill by using local weather and soil models to estimate the spread of the spill, determining the impact based on population location as well as geographic features such as rivers and water supplies, creating a short-term mitigation plan (perhaps based on chemical reaction models), and taking emergency response personnel by planning and coordinating evacuation, notifying hospitals, and so forth.”

“The Anatomy of the Grid” by Foster, Kesselman, and Tuecke

“A crisis management team responds to a chemical spill by using local weather and soil models to estimate the spread of the spill, determining the impact based on population location as well as geographic features such as rivers and water supplies, creating a short-term mitigation plan (perhaps based on chemical reaction models), and taking emergency response personnel by planning and coordinating evacuation, notifying hospitals, and so forth.”

“The Anatomy of the Grid” by Foster, Kesselman, and Tuecke

Supply chain management: Tracking and

Control

Supply chain management: Tracking and

Control

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Contents

� Can RFID help? How?

� Enterprise Service Computing?

� RFID: Value Proposition for Factory Integration?

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Contents



� Can Grid Computing help?

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RFID Tag

Copyright © http://www.scs-mag.com/reader/RFID_Edge/index.htm

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RFID Reader

Copyright © http://www.skyetek.com, www.roxan.co.uk/electronic/ images/333-3.html, www.ti.com, http://www.nokia.com/

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Bar Code

� Bar Code

A UPC is created using a 12-digit numeric sequence scheme. A

series of light and dark lines are used to represent a UPC code,

while a human readable numeric equivalent is given together

with the standard symbol. An example of a barcode looks like

0.03456.89234.6

Numbering System Character.Enterprise ID Number.Serial

Number (Model).Modulo check character

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EPC

� Electronic Product Code (EPC)

An EPC is created using a 96-bit numbering scheme. It consists

of an 8-bit header and three data partitions, i.e.,

02.0006A66.56271F.0003476AB

8 bits.28 bits.24 bits.36 bits

Header.Enterprise.Product.Serial Number

“The 96-bit EPC provides unique identifiers for 268 million

companies. Each manufacturer can have 16 million object

classes and 68 billion serial numbers in each class, more than

enough to cover all products manufactured worldwide for years

to come.”

EPCglobal Architecture Framework

11© EPCglobal Inc™

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EPCglobal Network: 5 Components

© EPCglobal Inc™

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The EPCglobal Network

© EPCglobal Inc™

realreal--time object movement datatime object movement data

Potential Benefits

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The EPCglobal Network™ Demonstration

� Product Authentication� Gillette (along with solution providers Sun Microsystems and VeriSign, and trading partner Wal*Mart) demonstrated how a missing or mis-delivered Venus Case could be identified and re-associated with its order.

� New Product Visibility� Procter & Gamble (P&G), solution providers TIBCO, IBM, VeriSign, and retailer Wal*Mart demonstrated how suppliers and retailers could utilize the EPCglobal Network to gain visibility into the store sales floor and backroom.

© EPCglobal Inc™

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Typical Example: DOD Logistics

Tagged Item

Physical WorldPhysical WorldPhysical World

Tagged Container

Tagged Item

• Fast (global real time)

• Accurate/precise• Easy to use• Cheap

(Standards)

• Fast (global real time)


(Standards)

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Wal-Mart's Supply Chain

Source: Teamsters, "Wal-Mart Organizing Update," Warehouse Newsletter (August 2000).

• Business Dynamics• Fast (global real time)


(Standards)

• Business Dynamics• Fast (global real time)


(Standards)

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The EPCglobal Network: Viable Solution?

� “Indeed, behind the scenes, the application is making use of the EPCglobal Network to direct it towards whichever resource is required at any given time. The EPCglobal Network itself is responsible for knowing where to point an application looking for information based on a particular EPC or class of EPCs. Similar to the Internet, the EPCglobal Network is continuously updated, and it will know within 60 seconds when EPC-tagged products have arrived and been read at various locations, whether these are manufacturers, retailers or distribution centers.”

© EPCglobal Inc™

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EPC & GIC & RFID

� Global Identification Code (GIC)

When an EPC is used as an object identifier, A GIC consists of

an 8-bit header and four or more data partitions, i.e.,

02.0006A66.56271F.0003476AB.IP.xxx

8 bits.28 bits.24 bits.36 bits.IP.options

Header.Enterprise.Product.Serial Number.IP.xxx

Internet

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Real Time Visibility: Possible? How?

Internet

Service

Server

Products arrive at

the gate of a

facility.

RFID reader

writer

Satellite

GPS

Source: GL AgilityTech, IncSource: GL AgilityTech, Inc

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Global Real Time VisibilityGlobal Real Time Visibility Solution?

ContainerContainer--levellevel

ItemItem--levellevel

Tracing Server

Ce llu la r

Ph one

DevicesGIC

Satellite

Universal Data Appliance Protocol ?

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Point-of-need Service Scenarios

Product Information Service Server

SS1: a traveler

needs assistance.

SS2: an overturned truck loaded

with hazardous chemicals.

SS3: a truck loaded

with commodity that

needs specific attention.

Information

linkage

Travel Information Service Server

Point-of-need Information Server

Logical view of

the IIS network

SS1

SS2,

SS3

Delivering JustDelivering Just--inin--time Intelligent Servicetime Intelligent Service?

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Healthcare Delivery Networks


Delivering Global Real Time ServiceDelivering Global Real Time Service?

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Distribution Center (Precise Location?)

1,150,000 sq. ft. WalMart Dry Goods Distribution Center

Copyright © www.schwob.com/ projectswalmart.htm, www.siemense-dematic.us

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Value Proposition (Warehouse Example)

� Cycle counting

� Operational Accuracy

� Labor saving

� Lower inventory

� Avoiding theft

� Reducing loss of sale

�� SupplySupply On DemandOn Demand

�� Sell one, replenish oneSell one, replenish one

From an IT perspective, How can we support it?From an IT perspective, How can we support it?From an IT perspective, How can we support it?

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Contents



� Can Grid Computing help?

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Middleware is everywhere. Can you see it?

www.ibm.com

RFID tags areeverywhere.

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Key Elements to an RFID-enabled Networks

Copyright © http://www.scs-mag.com/reader/2004/2004_04/logi0404/index.htm

Standards for Tracking & Integration

Framew

ork fo

r Tracking & In

tegratio

n

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Catching Up the Changes

Copyright © www.nwc.com

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Business Aligning IT?

Process Logic

Organi

zation

IT Infrastructure

ComplexComplex

DynamicDynamic

Thomas J. Burke, Advisory Software Developer, Rockwell Software Incorporated

Competitive Enterprise?

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� Multi-vendor

� Proprietary

� Complex information

flows

�Asynchronous Processing

�Multiple interfaces

�Mission Critical

�How to manage changes?

µ sec

msec1 sec

secs

min

hours

Thomas J. Burke, Advisory Software Developer, Rockwell Software Incorporated

A Complex System?

office-planning

controls

operations

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“Only the change is certain”

� The business world is rapidly changing. The revolutionary technology of the Internetthe Internethas led to the faster and more efficient interaction between customers, suppliers, and partners.

� A new trend is emerging where the performance and development of business processes is a collaborationcollaboration between business partners (Internally and externally).

http://www.bpmn.org/Documents/NWG-2001-09-01R4%20Charter.pdf

RFIDRFID�� EPC or GIC NetworksEPC or GIC Networks? ?

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BPM Merging With SOA Services

Java/J2EE

C++/Unix

.NET/Windows

MobileCICS/OS/390

DBMS MQ LDAP PKI

Source: Eric Newcomer and Greg Lomow

PeopleSoft SAPCustom/Legacy

Office/Exchange

SAS

Application LayerApplication Layer

TechnologyTechnology

LayerLayer

Web Services Platform

Services Layer:Services Layer:

(Web) Services (Web) Services

SOAP, WSDL, UUDI SOAP, WSDL, UUDI ……

BPMBPMBusiness Process Layer:Business Process Layer:

BPML/BPMNBPML/BPMN

BPMSBPMS

Integration PlatformIntegration Platform BPELBPEL

Modeling, Execution,Monitoring, Optimization

(Lifecycle management, cross-function, end-to-end business processes)

GIC �� Global Key?Global Key Enabled Enterprise Service Computing?��Services Design, Modeling,

Execution, Monitoring, Optimization

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Contents



� RFID: Value Proposition for Factory Integration?

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Controller

ProductionRequirements

Controller

PhysicalSystem

I/O Channels

Planner Scheduler Executor

TaskList

I/O Channel

System Model

PhysicalModel

SystemStatus

PhysicalConfiguration

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Control Hierarchy and Information Flow

Entry D/A D/A D/A

Plasma

Oven

Exit

Exception

3rd Opt

Overhead

Track

Wire Bonder Wire Bonder

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A simplified process flow and identify hierarchy

Chip

RFID Tag

P1 InStage

DieAttach

DieAttach

Cure

WireBond

Optical

Inspection

Mark

Singulation

Inspection

OutStage

Wafers in

cassette.

Strip in magazine.

(Typically each strip

holds 6 ~ 10 d ies and

each magazine stores 20

~ 30 strips.)

Chips in

tray. Pn

Each process has its

own specification

defining requirements

on set up, tools,

consumables, etc.

WaferSaw

Physical Identifier:

wafer cassette


strip magazine


individual chip

Magazine

Cassette

Magazine

Chip Chip Chip

Chip Chip

RFID Tag

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A generic process model

2 4 3

1 5

Part state (Delivery

In, Move In,

Processing, Move Out, or Delivery

Out), and other

pertinent product

and process

information can be stored in an RFID

tag. More

information can be

retrieved from its

host application using the GIC

technology.

2

4 1

5

3

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Synchronization using agents and GIC hierarchy

Factory Information

System (IP)

MCS MC

MC MC

Cell

Office-level

Information System

MCS: Material Control

System

MC: Machine Controller

2 4 3

1 5

GIC1 GIC2

Office-level

Information System

Different factory,

facility or partner on the

supply chain

Internet

GICn (GICs’

relations can be

part of optional

parameters stored

in a tag or data

source managed by

host applications)

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A framework for the implementation of RFID-enabled factory integration

Factory

ωu (Server)

Material

control server

Planner,

Scheduler,

Dispatcher

Database

Cell

Controller

Cell

Controller

Cell

Controller

XML

XML XML Business Integration Engine (BIE) –

Messaging-based Integration Middleware (XML conversion, synchronization algorithms, GIC

event manager, GIC reference services, etc.) : RFID-enabled Integration Backbone

Process service

controller

Equi pment - speci f ic

Model

BUS

Dow nloadabl e

I nter f ace Engi ne


Model

BUS

Dow nloadabl e

I nter face Engi ne


Model

BUS

Dow nloadabl e



Model

BUS

Dow nloadabl e



Model

BUS

Dow nloadabl e

I nter face Engi ne


Model

BUS

Dow nloadabl e

I nter face Engi ne


Model

BUS

Dow nloadabl e



Model

BUS

Dow nloadabl e



Model

BUS

Dow nloadabl e


Value Proposition

� Standardized Data Exchange

� Ease of Factory Integration

� In Support of Fully Collaborated Supply Chain

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Questions?Questions?

I really appreciate your attention and time.

[email protected]