Leistungsbeschreibung V3 EN · Central integration level according to ISA 95 standard, specially designed for manufacturing applications, for optimized integration of individual systems

ISTOS.COM

PLANNING SOLUTIONS Service specification

1 General service description

2 Service description modules

3 Additional modules

4 Technology

5 Service


With PLANNING SOLUTIONS, ISTOS GmbH offers an easy start to optimize PRODUCTION PLANNING. The solution includes interfaces to order manage-ment / ERP, business data entry and control center. They form the foundation for optimized planning and transparent production.

The challenge in planning is always the limited resources, a timely response from the workplaces and ensuring transparency in the factory floor and in the management. The solution therefore consists

of the applications PRODUCTION PLANNING, PRO-DUCTION FEEDBACK and PRODUCTION COCKPIT.

The PRODUCTION PLANNING application is an intel-ligent planning system that enables automated PRO-DUCTION PLANNING according to defined optimiza-tion goals and with limited resources. PRODUCTION FEEDBACK is the application for direct feedback of production progress from the workplace. Both toge-ther create a continuous flow of information between planning and production, allowing for quick reactions and direct intervention in case of problems.

2




4 Technology

5 Service

In addition, production and machine data can be visu-alized in the PRODUCTION COCKPIT so that transpa-rency can be provided throughout the entire production process. In addition, the solution bene-fits from open technology, the modular micro service architecture with apps, and the Integration Layer, which enable inventory systems such as legacy systems to integrate an ERP system as required and to communicate between shop floor and office floor. For many customers, this is also the first and decisive step for the integrated networking of their systems and thus for Industry 4.0.

PRODUCTION PLANNING will be installed on site. The PRODUCTION FEEDBACK, TEAM MAN-AGEMENT AND COCKPIT PRODUCTION applications are for WEB use and are offered as a soft-ware-as-a-service.

By 2019, all applications will be published by PLAN-NING SOLUTIONS (PRODUCTION FEEDBACK, TEAM MANAGEMENT AND PRODUCTION COCKPIT).

Technical requirements

The hardware requirements for these products depend on the requirements of the customer. The specification of a reference hardware (server) has not yet been made (will be replenished).

APPLICATIONS AT A GLANCE

Core applications

+ PRODUCTION PLANNING: Application for extended planning and Scheduling against limited resources for dynamic planning of production orders

+ PRODUCTION FEEDBACK: Solution for the operation/machine data (BDE/MDE) and feedback to the current production status and incoming orders

+ PRODUCTION COCKPIT: Dashboard for the visualization of machine- and process-relevant information for a manufacturer- independent overview of production

Additional modules

+ TEAM MANAGEMENT+ GUIDED SYSTEMS+ MASTER DATA MANAGEMENT

Technology

+ INTEGRATION LAYER: Central integration level according to ISA 95 standard, specially designed for manufacturing applications, for optimized integration of individual systems into existing IT landscapes

+ ERP/MES CONNECTOR: Standardized, easy to parameterize interface for connecting a Manufacturing Execution System (MES) to any Enterprise Resource Planning (ERP) system

3




2.1 PRODUCTION PLANNING


4 Technology

5 Service

PRODUCTION PLANNING is an APS (Advanced Plan-ning & Scheduling) software. The soft-ware provides an easy entry into the optimization of PRODUCTION PLANNING taking into account marginal results.

In addition to adherence to schedules, planning must take into account the capacities of different machines, employees with different qualifications, materials or also the supplies from suppliers and customers and optimize them according to costs, set-up times and lead times.

2.1 PRODUCTION PLANNING ― Installed on Premise

TECHNICAL REQUIREMENTS

Client hardware

+ CPU 2Ghz+ 1GB RAM (required memory depends on

planning model, 2 GB recommended) + 200MB hard drive space+ Monitor min. 1280x1024, full-HD

recommended

Client software

+ MS Windows 7 or later

4

PRODUCTION PLANNING resolves the complexity in such a way that the user is able to auto-matically plan with limited resources and simply drag and drop orders, and the recalculation of all processes remains in the background according to the stored optimization targets

The interactive planning tool finds PRODUCTION PLANNING has established itself in the digital net-working between ERP (Enterprise Resource Planning) and the shop floor.

This is what PRODUCTION PLANNING offers custo-mers for order and production optimization:

+ Order optimization through planning algorithm with several variables - based on ISSOP optimi-zation technology

+ Innovative multi-resource planning (machinery, personnel, production resources),

+ Classification of executive orders in current planning

+ Visualization of standstills and malfunctions

+ Bottleneck control

+ Consideration of quality assurance

+ Visualization of the planning results in the gra-phical control station

+ Overall analysis of all production orders with planning information

+ Simulative Scenario Manager

5



2.1 PRODUCTION PLANNING


4 Technology

5 Service

PRODUCTION FEEDBACK is a web-based user data collection (BDE) software. The following core features are included:

+ Display of all orders

+ Recording the actual data from the production

+ Reporting of possible faults

Production status, results with used up times and num-ber of produced time and the produced parts as well as possible disturbances are reported back to the manu-facturing planning. This enables a flexible and short-term reaction to changes and thus agile production.

2.2 PRODUCTION FEEDBACK ― Web-based

TECHNICAL REQUIREMENTS

PRODUCTION FEEDBACK was developed for use as a web application. The following brow-sers are currently supported:

+ Google Chrome

Communication with other systems is con-trolled via a Integration Layer.

6



2.2 PRODUCTION FEEDBBACK


4 Technology

5 Service

The goal is usually the short-term fulfill-ment of cus-tomer requirements while taking into account on-time delivery, costs and quality assurance.

PRODUCTION FEEDBACK is divided into two areas. Firstly, the actual status is entered directly by the ope-rator via a terminal, this is called operator data acqui-sition (ODA). Secondly, data can be taken di-rectly from the machine as a status, this is called machine data acquisition (MDA).

An example of this process could be:

Assembly or production orders are created in an ERP system. These are transferred to a planning sys-tem for detailed planning, which plans the orders in detail and then transfers them to PRODUCTION FEEDBACK. These production orders are now available to the user at the user at the terminal or the machine. Continuous feedback of current status can now take place during the production process. Based on this real-time feed-back, the planner can adjust and update schedules directly.

7



2.2 PRODUCTION FEEDBBACK


4 Technology

5 Service

PRODUCTION COCKPIT is an application that acces-ses information from different preconfigured sources (applications) and displays them in an overview (herein-after referred to as the dashboard).

The dashboard is created using a dashboard designer, which allows different information to be displayed in the form of widgets and configured in terms of size, posi-tioning and widget-specific options. Predefined widgets are provided with the PRODUCTION COCKPIT.

2.3 PRODUCTION COCKPIT ― web-based

TECHNICALREQUIREMENTS

+ Customers use PLANNING SOLUTIONS applications and/or DMG MORI Software products

Client hardware

+ 2 GHz CPU+ 1GB RAM+ 200 MB hard disk space+ Monitor, preferably with full HD resolution

Client software

+ MS Windows 7 or later+ Installed web browser (IE 11.0.40, Google

Chrome 61.0, Mozilla Firefox 55.0)+ (wireless) 100 Mbit network connection (LAN

or WLAN) for communication with other systems

8



2.3 PRODUCTION COCKPIT


4 Technology

5 Service

These are widgets that display data from PLANNING SOLUTIONS applications as well as from other DMG MORI applications. They can be selected and, if necessary, configured in the Dashboard Designer.

PRODUCTION COCKPIT is the frame application that uses widgets from other applications. Purcha-sing COCKPIT does not mean that other applications are automatically widget-compatible. All widgets are configurable, but always as part of a core application. Individual COCKPITs can be created but require soft-ware development environments and the appropriate skills.

This gives the user the ability to create dashboards and overviews for his specific application to quickly collect and disseminate information and ensure transparency within the company. The following com-po-nents are used to achieve this:

+ A configurable dashboard panel that displays all dashboards, giving an overview of all the dash-boards and the ability to navigate to each dashboard’s content

+ A Dashboard Designer that allows you to create your own overviews/views by adding predefined widgets and configuring them in terms of size and position on the dashboard

+ Standard widgets that can display information and be added to the dashboard independently of other applications, for example to display a clock, individually defined text fields or graphics

+ Custom Widgets Feature that makes it possi-ble to make self-created widgets yourself (e.g. im-port) to cover the individual needs of the customer beyond the Planning Solutions appli-

cations as well as other DMG MORI or CELOS worlds and that can be incorporated into third-party systems in CELOS Cockpit, for example: No limitation of the application on DMG MORI or CELOS products

+ Share & export functionality to share crea-ted dashboards/overviews with other CELOS Cockpit users, to export to other files/links and to print, if necessary

+ DMG MORI widgets, which display the relevant information, e.g. Planning Gantt Chart from Pro-duction Planning, in a widget, in order to add it to a dashboard and to adapt it to a certain extent

This application and its features offer a tool for visualization and communication of information for the customer in a wide variety of applications and the option for individual configuration.

Target devices for the application are desk-top PCs with keyboard and mouse, devices with touch con-trol, tablets and smartphones. The application is optimized for a full HD display and works at 16:9 resolutions.

This service description only covers the frame application, with which it is possible to create individual dashboards with the aid of widgets. It provides standard widgets. The requirements for the individual DMG MORI widgets are not part of this product description.

9



2.3 PRODUCTION COCKPIT


4 Technology

5 Service


3.1 TEAM MANAGEMENT ― Web-based


TEAM MANAGEMENT is developed as a browser application. The following browsers are supported:

+ Google Chrome+ 2. MS IE 11 or higher

Communication with other systems via the Integration Layer is recommended.

TEAM MANAGEMENT is an additional module of PRODUCTION PLANNING. Through the application, shift plans, vacation spots, legal tasks and the quali-fication of individual employees can be implemented and created for the production plan.

The following functionalities are included:

+ Shift Plan Management (SPM)The customer can manage shift schedules in SPM and is supported by the system, which takes into account automated planning, regulation compli-ance with defined processes and the availability of employees and machines.

10




3.1 TEAM MANAGEMENT

4 Technology

5 Service

+ Human Resource Management (HRM)The customer can store further details of the employee in the HRM module. Examples include busi-ness and private contact data, company-specific information, special data such as remaining shift time and leave ent-itlement. There is also a personal calendar in which sick leave and holidays can be entered.

+ Calendar Management (CM)The CM module allows the customer to set up specific calendars for different work groups, plants and/or departments, etc. The customer can define the visibility of the calendar and can enter one-off and recurring appointments. The different group members can follow the respective calendars to be notified about chan-ges or appointments at any time.

+ Skill Management (SM)The Skill Management Module assists the cus-tomer in managing the various qualifications that they would like to maintain. Users can add their own new qualifications, define different qualification lev-els or select a matrix under which the respective users and qualifications can be displayed. Similar to a filter.

All the modules mentioned are in continuous data exchange with each other. The maximum possible efficiency is therefore achieved by installing, main-taining and using all the aforementioned applications.

TEAM MANAGEMENT was developed with the aim of communicating with other customer systems (ERP, HR systems, etc.). Using the Integration Layer, exter-nal data are imported from these other systems, can be edited in TEAM MANAGEMENT (TM) and then transferred back to the customer’s systems via the Integration Layer. Other systems can receive the data from the Integration Layer and continue to use them in their local system.

TEAM MANAGEMENT is marketed as an add-on to PRODUCTION PLANNING. On request, the module can also be purchased separately.

11




3.1 TEAM MANAGEMENT

4 Technology

5 Service

3.2 GUIDED SYSTEMS ― Web-based




3.2 GUIDED SYSTEMS

4 Technology

5 Service

In the processing industry, digitization is a key fac-tor for the future competitiveness of many compa-nies and is holistically supported by the products of ISTOS GmbH. The successful implementation of digiti-zation solutions in companies largely hinges on whether the relevant employees can be intuitively and efficiently taught the necessary skills to use the new digital solutions.


GUIDED SYSTEMS is developed as a brow-ser application. The following browsers are supported:



12

The ‘Guided Systems’ product was developed for this purpose. This product develops modern training solutions, which can be used by training academies and as part of induction phases for new products, to quickly and safely help employees get started with using the new digital solutions.

Guided Systems allows the use of modern training and support solutions such as interactive, questi-on-guided manuals, demonstration videos, online courses and much more. It can be used as a ful-ly-fledged Learning Management System and ena-bles the connection to any CMS.

In addition to training solutions, Guided Systems will make it possible to respond directly to machine error in future. After the error message has been transferred to the system, solutions are either issued directly from a knowledge database or, if this is not possible, a contact to a service technician is estab-lished.

The application’s modular, easily customizable SANDBOX architecture gives developers the ability to easily connect, group and arrange content. New content can be created and published via an API.

Guided Systems can be used as an online applica-tion in a web browser, as a CELOS application or natively on mobile devices.




3.2 GUIDED SYSTEMS

4 Technology

5 Service

13

3.3 MASTER DATA MANAGEMENT

The MASTER DATA MANAGEMENT (MDM) is the central data management system for master data and provides a uniform definition and management of critical data from all applications via a reference source. Standardization and the common data sha-ring framework provide a leading instance of data relevant to all applications.





4 Technology

5 Service


GUIDED SYSTEMS is developed as a brow-ser application. The following browsers are supported:



14

The Data from applications and modules remain stored in the MDM, even if an application should be removed. This provision secures a permanent and autonomous ability to run the other modules with the stored data. MDM is the data backup that communicates with both intermodular and exter-nal programmes by means of the Integration Layer. The system settings support customization of fur-ther applications and interfaces based on the wishes and expectations of the customer

The following modules have been implemented so far:

+ Equipment

+ Basic Information / Organisational Structure

Note: MDM is an integral part of the framework application of PRODUCTION PLANNING Solutions and is not suitable for managing own master data independently of Planning Solutions.

15





4 Technology

5 Service

Many manufacturing companies plan on networ-king applications and machines in order to make production more efficient and flexible. This radi-cally changes the demands on the IT infrastruc-ture. Moving forward, the IT infrastructure must be continually able to adapt to changing data struc-tures and new business requirements to enable permanent end-to-end communication between applications in companies and beyond and to ensure interoperability between all systems.

On the other hand, implementing different software solutions today is often very timeconsuming and costly, since each solution provider works with their own data formats and a proprietary data structure. What’s more, the interfaces of new applications and cloud services have to be extensively adapted in order to establish communication among each other.

The Integration Layer from ISTOS is a consistent integration layer with a standardised data struc-ture and data description. It replaces the com-plicated network of end-to-end connections in the application landscape with a communication infrastructure that is used by all connected end-points (applications, service providers and users), allowing them to communicate with each other on the basis of the recognised data format (JSON) and the industry standard ISA 95.

Compared to other Enterprise Service Bus sys-tems, the special feature of the ISTOS Integration Layer is the fact that it specialises in the manu-facturing industry and therefore specifically allows scenarios where applications can be integrated in production processes and dataintensive applicati-ons in production.




4 Technology

4.1 Integration Layer

5 Service

DETAILS ON FUNCTIONALITIES:

- Common data formats (JSON)- Recognised industry standards (ISA 95)- Communication protocol (MQTT)- Data mapping and transformation - Routing and orchestration- API management- Adapters for Software-as-a-Service (SaaS) and locally installed applications.

Note: The Integration Layer cannot be pur-chased separately. It is used to exchange data between the individual applications of Planning Solutions and cannot be used as a standalone product.

16

4 Technology

4.1 Integration Layer

The implementation effort for PRODUCTION PLANNING depends on the specific requirements of the customers and general conditions on site. When planning up to 50 resources (machines and manual workplaces), an average effort of approx. 20 days can be expected. For the intro-duction of the PLANNING SOLUTIONS or indivi-dual products from it an inventory of the existing IT system landscape and desired requirements is required. Depending on the scope, a one- to two-day workshop will be offered. This inventory and requirement entry includes the comprehensive consultation of the customer on site with regard to the implementation and mapping possibilities of existing machines, work steps and production processes by PLANNING SOLUTIONS, assigns the planned implementation project already in the first stages of realization and determines with the cus-tomer the necessary preparatory ones Activi-ties. Furthermore, the customer receives his request list, which represents the basis of the consequent project realization.

Based on the workshop, the customer can make a binding offer for the implementation of PLANNING SOLUTIONS.




4 Technology

5 Service

5.1 Requirements workshop at the customer site

17

5 Services

5.1 Requirements workshop at the customer site

We offer the following procedure:

Step 1: Project startWith the start of the project the further detailing of the introduction of PLANNING SOLUTIONS and the detailed planning of the work packages and milestones for all project participants takes place.

Step 2: Interface programmingIn accordance with the definition in the detailed specification, the programming or adaptation of the interfaces for the data exchange between the Integration Layer of PLANNING SOLUTIONS and the company-specific third-party systems at the customer‘s company takes place in this step.

Step 3: Installation and test setupOnce the interfaces have been completed, the PLANNING SOLUTIONS will be set up by the cus-tomer company to test its functionality.

Step 4: CustomerIn this project step, the customer-specific adjust-ments defined in the detailed specification in PLANNING SOLUTIONS, which go beyond the standard application, are implemented.

Step 5: System validation and commissioningAfter successful completion of project step 4, the entire system is commissioned. In this phase, a close cooperation with the customer is necessary. The obligation of the client to cooperate is to pro-vide the required internal resources. The test with live data forms the basis for the analysis of the

achieved planning results. The planning quality is continuously improved over several iteration steps. The result is an installation of the solution adapted to the customer‘s individual requirements, which complies with the goals defined in the detailed specification.

Step 6: TrainingThe training package includes an introduction to the basics of working with PLANNING SOLUTI-ONS and user training. For the product PRODUC-TION PLANNING special attention is paid to the creation of plan-ning scenarios, their interpreta-tion, the use of control parameters and target cri-teria to optimize the re-sults. In addition, content for the simulation of scenarios, evaluation options in the control center, work with the available ana-lysis tools and the creation of required reports are trained.

Further questions regarding our products, please contact your known contact or send an email to: [email protected]




4 Technology

5 Services

5.2 Implementation & training

18

5.2 Implementation & training

PLANNING SOLUTIONS

– Intelligent solutions for the digitized factory!

ISTOS GmbH is a member of the DMG MORI Group ISTOS GmbH and stands for “Innovative Software Technolo-gies for Open Solutions“. We develop applications for the medium-sized manufacturing industry. Our goal is to establish network-based manufacturing prosesses across all machines along today’s supply and value chains, and to provide data-intensive applications for setting up consistent digital value-adding network of tomorrow. .

Contact us! We would be pleased to respond to queries and offers regarding our products.

Isabell Kreuzau, Head of SalesTel.: +49 (0)151 [email protected]

ISTOS GmbH, Kaistraße 16a, 40221 Düsseldorf

ISTOS.COM

1118

_EN

C

hang

es r

eser

ved.

Documents

Leistungsbeschreibung V3 EN · Central integration level according to ISA 95 standard, specially designed for manufacturing applications, for optimized integration of individual systems