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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]
2
ControlGen’s Real Time Visibility Solution
http://www.controlgen.com
3
Point-of-care Service Scenarios
Service-oriented Community/Society
Google?, or Yahoo!?
• Fast (real time)
• Accurate• Easy to use• Cheap
(Standard)
4
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.
Service-oriented Community/Society
“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
5
Contents
� Can RFID help? How?
� Enterprise Service Computing?
� RFID: Value Proposition for Factory Integration?
6
Contents
� Can RFID help? How?
� Enterprise Service Computing?
� Can Grid Computing help?
7
RFID Tag
Copyright © http://www.scs-mag.com/reader/RFID_Edge/index.htm
8
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™
13
The EPCglobal Network
© EPCglobal Inc™
realreal--time object movement datatime object movement data
Potential Benefits
14
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™
15
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)
• Accurate/precise• Easy to use• Cheap
(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)
• Accurate/precise• Easy to use• Cheap
(Standards)
• Business Dynamics• Fast (global real time)
• Accurate/precise• Easy to use• Cheap
(Standards)
17
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™
18
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
20
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 ?
21
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?
22
Healthcare Delivery Networks
Service-oriented Community/Society
Delivering Global Real Time ServiceDelivering Global Real Time Service?
23
Distribution Center (Precise Location?)
1,150,000 sq. ft. WalMart Dry Goods Distribution Center
Copyright © www.schwob.com/ projectswalmart.htm, www.siemense-dematic.us
24
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?
25
Contents
� Can RFID help? How?
� Enterprise Service Computing?
� Can Grid Computing help?
26
Middleware is everywhere. Can you see it?
www.ibm.com
RFID tags areeverywhere.
27
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
28
Catching Up the Changes
Copyright © www.nwc.com
29
Business Aligning IT?
Process Logic
Organi
zation
IT Infrastructure
ComplexComplex
DynamicDynamic
Thomas J. Burke, Advisory Software Developer, Rockwell Software Incorporated
Competitive Enterprise?
30
� 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
31
32
“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? ?
33
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
34
Contents
� Can RFID help? How?
� Enterprise Service Computing?
� RFID: Value Proposition for Factory Integration?
35
Controller
ProductionRequirements
Controller
PhysicalSystem
I/O Channels
Planner Scheduler Executor
TaskList
I/O Channel
System Model
PhysicalModel
SystemStatus
PhysicalConfiguration
36
Control Hierarchy and Information Flow
Entry D/A D/A D/A
Plasma
Oven
Exit
Exception
3rd Opt
Overhead
Track
Wire Bonder Wire Bonder
37
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
Physical Identifier:
strip magazine
Physical Identifier:
individual chip
Magazine
Cassette
Magazine
Chip Chip Chip
Chip Chip
RFID Tag
38
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
39
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)
40
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
Equi pment - speci f ic
Model
BUS
Dow nloadabl e
I nter face Engi ne
Equi pment - speci f ic
Model
BUS
Dow nloadabl e
I nter f ace Engi ne
Equi pment - speci f ic
Model
BUS
Dow nloadabl e
I nter f ace Engi ne
Equi pment - speci f ic
Model
BUS
Dow nloadabl e
I nter face Engi ne
Equi pment - speci f ic
Model
BUS
Dow nloadabl e
I nter face Engi ne
Equi pment - speci f ic
Model
BUS
Dow nloadabl e
I nter f ace Engi ne
Equi pment - speci f ic
Model
BUS
Dow nloadabl e
I nter f ace Engi ne
Equi pment - speci f ic
Model
BUS
Dow nloadabl e
I nter f ace Engi ne
Value Proposition
� Standardized Data Exchange
� Ease of Factory Integration
� In Support of Fully Collaborated Supply Chain
41