Conference: 14th IEEE International Conference on Industrial Informatics, INDIN 2016. Futuroscope-­Poitiers, France – July 18-­21 2016 Title of the paper: An approach for integrating legacy systems in the manufacturing industry Authors: Naveen Govindarajan, Borja Ramis Ferrer, Xiangbin Xu, Angélica Nieto, José L. Martinez Lastra

1. An approach for integrating legacy
systems in the manufacturing industry
Date: July, 2016
Contact information
Tampere University of Technology,
FAST Laboratory,
P.O. Box 600,
FIN-­33101 Tampere,
Finland
Email: fast@tut.fi
www.tut.fi/fast
Conference: 14th IEEE International
Conference on Industrial Informatics,
INDIN 2016. Futuroscope-­Poitiers,
France – July 18-­21 2016
Title of the paper: An approach for
integrating legacy systems in the
manufacturing industry
Authors: Naveen Govindarajan, Borja
Ramis Ferrer, Xiangbin Xu, Angélica
Nieto, José L. Martinez Lastra
If you would like to receive a reprint of
the original paper, please contact us

2. An approach for integrating legacy
systems in the manufacturing
industry
Authors: Naveen Govindarajan, Borja Ramis Ferrer, Xiangbin Xu,
Angélica Nieto, José L. Martinez Lastra
Tampere University of Technology, Tampere, Finland
{naveen.govindarajan, borja.ramisferrer, xiangbin.xu,
angelica.nieto, jose.lastra}@tut.fi
Tampere University of Technology,
Factory Automation Systems and Technology Lab
14th IEEE International Conference on Industrial Informatics,
INDIN 2016. Futuroscope-­Poitiers, France – July 18-­21 2016

3. Outline
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An approach for integrating legacy systems in the
manufacturing industry
3
• Introduction
• Motivation
• Objective
• Legacy Systems in the industry
• C2NET project
• PLANTCockpit OS
• The Approach
• Proof of concepts
• Conclusions and further work

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manufacturing industry
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Introduction
• Enterprise System Integration
– Necessity
– Industries want to integrate existing systems
with modern systems
• Integration Challenges
– Manufacturing environment is highly dynamic
– Huge volume of data in different format
• Cloud Collaborative Manufacturing Networks
(C2NET) project http://c2net-­project.eu/

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Motivation
• Enterprise systems are deployed based on
the latest technology
• Technology Advancements is inevitable
• Necessity to modernize infrastructure
• Modernization makes integration easier

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Objective
• An approach for…
• Integrating existing industrial legacy systems
– Accessing external data source systems,
– Collecting and transforming the incoming
system specific data
• Required by the C2NET project

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Legacy Systems in the
industry (1/2)
• Industry requires dynamic systems
– Information generated and consumed
changes continuously
• Systems should be interoperable
• Systems should adapt to frequently changing
business market

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Legacy Systems in the
industry (2/2)
• Automation Pyramid of ISA-­95
– Enterprise Resource Planning (ERP)
– Manufacturing Execution Systems (MES)
– Supervisory Control and Data Acquisition
(SCADA)
• Efficient integration facilitates flexible supply
chain of data between heterogeneous systems.

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C2NET project: concept
VALUE&CHAIN&
OPT& DCF&
Plans&Op5miza5on&
Services&
COT&
C2NET&
Sharing&Distribu5on&Assests&
Sharing&Logis5cs&Assets&
Sharing&&Product&Stocks&
Sharing&&Components&Stocks&
Sharing&Manufacturing&Assests&
Sharing&Logis5cs&Assets&
Stocks&and&
Manufacturing&Real&
Time&Data&Collec5on&
Suppliers&Events&
Procurement&Plans&
Collabora5ve&
Decision&Making&
Produc5on&Plans&
Collabora5ve&
Decision&Making&
Distribu5on&Plans&
Collabora5ve&
Decision&Making&
Stocks&and&Sales&Real&
Time&Data&Collec5on&
Suppliers&Events&
Manufacturing&Real&
Time&Data&Collec5on&
Manufacturers&Events&
AUTOMOTIVE&USE&CASE&
METALWORKING&SME’s&NETWORK&USE&CASE&
DERMONCOSMETICS&USE&CASE&
Collabora5on&
Services&
Data&&Collec5on&&&
Storage&Services&
Sharing&Manufacturing&Assests&
Sharing&Logis5cs&Assets&
OEM&USE&CASE&
Sharing&Manufacturing&Assests&
Sharing&Logis5cs&Assets&/&Sharing&&Components&Stocks&

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C2NET project: architecture

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C2NET project: architecture

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PLANTCockpit OS (1/2)
• Platform that facilitates the integration of
systems: http://www.tut.fi/plantcockpit-­os/
• Data Collection
• Process optimization
• Monitor and control intra-­logistical process
• Integration of different layers of Automation
Pyramid

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PLANTCockpit and the
Automation Pyramid
* “D3.3 -­ PLANTCockpit White Paper -­ PLANTCockpit_D3.3_Public.pdf.” [Online].
Available:http://www.plantcockpit.eu/fileadmin/PLANTCOCKPIT/user_upload/PLANTCockpit_D3.3_Public.pdf. [Accessed: 1-­June-­2016].
PLANTCockpit OS (2/2)

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The Approach (1/5)
• The approach is implemented for accessing
external data source, collecting and transforming
incoming system specific data
• The C2NET main objective:
– Facilitates supply network optimization of
manufacturing and logistical assets
• PLANTCockpit OS solution to integrate systems

15. The Approach (2/5)
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• C2NET Data Collection Client (DCC)
– Responsible for data collection
– Heterogeneous data sources
– Transferring data to corresponding systems
• PLANTCockpit OS enables C2NET DCC to
establish connection with legacy systems

16. The Approach (3/5)
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• C2NET Data Collection Client

17. The Approach (4/5)
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• PLANTCockpit OS solution employs Function
Blocks (FBs) based on the IEC-­61499
• FBs
– Increases Flexibility
– Re-­usable
– Re-­configurable
– FB Schema
– Business logic
– Instantiable
Robert Lewis, “Modelling Control Systems Using IEC 61499: Applying Function
Blocks toDistributed Systems”, 2001, 192 pages, ISBN: 9780852967966

18. The Approach (5/5)
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• FB adapters
– Establishes connection
– Integrates with ERP, MES
and SCADA systems
– Collects shop floor data
from heterogeneous data
sources

19. Proof of concept: use case
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• Fluidhouse Oy (FH) offers advanced hydraulic
and oil lubrication solutions and assembly
services for industry
• FH allocates work hours to each employee
based on certain criteria and skillset
• Currently, the work time allocation of the
company resources is done manually
• The objective of this use case to automatically
perform this task

20. Proof of concept: Components
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• Function Block
– Creates a query from user parameters
• Database Adapter:
– Connects to the external ERP database system
• Message Broker
– Communicates between FBs (Apache ActiveMQ)
• Routing
– Routes messages between FBs (Apache Camel)
• Enterprise Service Bus (ServiceMix)

21. Proof of concept: Implementation
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22. Proof of concept: Implementation
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1 2
3
4

23. Proof of concept: DB to test
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24. Proof of concept: Results
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Project tasks à 1st week 2016 – 5th week 2016
Budgeted hours à 200 h
FB
MASTER
Query execution
Within DB Adapter

25. Proof of concept: Results
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26. Proof of concept: Results
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• ResourceID 4
• Full allocation in first 5 weeks of 2016
• Total = 8 + 12 + 30 + 35 + 35 = 120 h
• ResourceID 5
• Full allocation in first 4 weeks of 2016
• 2 hours allocated in 5th week of 2016
• Total = 16 + 32 + 30 + 2 = 80 h
• ResourceID 5 + ResourceID 4 = 200 h

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Conclusions and further work
• This paper presents an approach for integrating
legacy systems in the manufacturing industry
• The FB-­based approach facilitates the
integration of enterprise systems and addresses
the heterogeneity of the system
• FH will benefit of the presented research work
because automates a process currently done
manually
• Test different types of FBs (distinct business
logic)

28. Acknowledge
• The research leading to these results has
received funding from the European Union’s
Horizon 2020 research and innovation program
under grant agreement n° 636909,
correspondent to the project shortly entitled
C2NET, Cloud Collaborative Manufacturing
Networks
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