Multinational Steel-Making Company (“The Company”) -

Manufacturing Execution System (MES) and the Process Control System (PCS)

CASE STUDY FOR MANUFACTURING

SPEEDIT

￭ Overview￭ Problems￭ Solutions￭ Results￭ Technical Details

AGENDA

In-Memory Database Solution

CASE STUDY FOR MANUFACTURING

+ Overview

AltibaseAltibase is provider of In-Memory database solutions for real-time access, analysis and distribution of high volumes of data in mission-critical environments.

Multinational Steel-Making Company (“The Company”)

Top 5 steel makers in the world.

SummaryAltibase helped The Company reduce the number of technical failure points which resulted in an ongoing cost saving of over $3M per year.

In-Memory Database Solution

+ ProblemsThe Company could not promptly deliver product to its customers as its legacy system was becoming obsolete.

The Company required seamless operation of separate systems but its legacy DBMS could not handle it.

Marked by data redundancy, low performance and increasing resource deterioration, The Company’s Manufacturing Execution System (MES) and the Process Control System (PCS) ran inefficiently.

The Company was losing its stronghold on competition due to an inability to keep deadlines on product delivery. Increasing demands on order flow worsened the situation.

A critical step toward resolution was to integrate MES and ‘PCS’ but this necessitated an upgrade to The Company’s Train Control System. The upgrade required a DBMS with High Availability and the ability to quickly process massive volumes of data from its molten metal transporting trains at its 5 blast furnaces1.

In-Memory Database Solution1) One of The Company’s 5 blast furnaces possesses the highest production capacity in the world.

+ Solution The Company deployed ALTIBASE HDB In-Memory DBMS after a

successful benchmark test with Oracle TimesTen and IBM SolidDB1. ALTIBASE HDB provided The Company with consistency, high speed and superior reliability with its High Availability2 feature. The Company has the ability to leverage ALTIBASE HDB’s flexibility by incorporating, ‘ALTIBASE Adapter for Oracle’ which effortlessly integrates data between Oracle and ALTIBASE HDB3.

In-Memory Database Solution

1) ALTIBASE HDB outperformed Oracle TimesTen in speed and reliability while IBM SolidDB exited the benchmark test midway.2) ALTIBASE HDB’s built-in Replication feature enables business continuity with flexible configuration.3) ALTIBASE HDB has built-in functionality (a tool) to apply data to and from Oracle.

+ Results The Company is endowed by its revamped Train Control System. Built on an

ALTIBASE HDB base after only 5 months of development time, The Company has industry-leading flexibility, reliability and performance.

The Company has full control over its metal transporting trains that are armed with the ability to store and analyze 40,000 bits of sensor data per second. The data is collected from 4000 railroad sensors and readied for instant availability.

The Company supplies product to customers on time and can easily scale with demand.

The Company has initiated integration of MES and ‘PCS’ bolstered by High Availability and reliability with its simple user interface – saving money and time.

The MES and ‘PCS’ integration has eliminated redundant data and drastically reduced the number of technical failure points contributing to a projected cost savings of over $300,000.00 per year.

In-Memory Database Solution

+ Technical Details The Company achieved exceptional results by leveraging key features of

ALTIBASE HDB, specifically in the areas of high-performance and high-availability.

In-Memory Database Solution

AP Server

ALTIBASE HDBIn-Memory DBMS

Active-Standby

Oracle DBMS ALTIBASE HDBIn-Memory DBMSbatch

PLC PLC PLC PLC

I/F Server

Sensor Sensor Sensor Sensor Sensor Sensor… … ……

+

The Company was using a control system for controlling the flow of molten metal between its blast furnaces and production lines. With a legacy on-disk DBMS in its back-end, the control system’s capacity for collecting information from sensors was ~ 400 transactions per second (TPS), which was inadequate for detecting and responding to process status changes in real time.

The Company decided to replace the legacy on-disk DBMS with a high-performance In-Memory DBMS. To determine the best alternative technology, The Company conducted benchmark tests with Oracle TimesTen, IBM SolidDB and ALTIBASE HDB. The Company’s benchmark tests focused on four primary requirements; real-time DBMS performance, interoperability with WebLogic application server, failover functionality and interoperability with Oracle on-disk DBMS for data synchronization.

ALTIBASE HDB was the clear winner by meeting and exceeding all four primary requirements. For the real-time DBMS performance requirement, ALTIBASE HDB provided the Company with unsurpassed performance of 2500 TPS (transactions per second).

As a result, the Company officially announced that they would use ALTIBASE HDB for production and manufacturing management purposes in August, 2011. Since then, the Company has adopted ALTIBASE HDB for other internal projects, including a Railroad Control System.

In-Memory Database Solution

Performance

+

In addition to the performance issues, with the increased volumes of transactions, The Company’s conventional on-disk database had reliability and stability issues resulting in system outages.

Using the ATLIBASE HDB’s built-in replication feature, The Company implemented ALTIBASE HDB based on Active-Standby HA architecture. In this architecture, ALTIBASE HDB replication feature maintains an up-to-date backup of the database on a second system. In the event of unexpected master server unavailability, immediate service resumption initiates from an identical database on an alternate server. The Company is empowered by a non-stop operating environment with improved reliability and fault-tolerance. ALTIBASE HDB has never failed, and continues to provide reliable service since it was first put in production by The Company in May 2011.

In-Memory Database Solution

High-Availability (HA)

In-Memory Database Solution

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