Manufacturing
Transcription
Manufacturing
POSCO FIORANO CUSTOMER SOLUTION Published: July 2009 POSCO uses Fiorano Enterprise Service Bus™ for flexible Integration and Business Process Automation Steel manufacturing is one of the most complex processes. POSCO is facilitating the Steel Manufacturing process by leveraging the power of technology to simplify many business related tasks such as connecting the manufacturing systems to its digital management system called POSPIA. POSPIA consists of POSCO’s e-Sales and e-Purchasing and across the company’s value chain over the web. To help make this happen, the company selected Fiorano Enterprise Service Bus™ (Fiorano ESB™) as its Integration Platform for its flexible Integration and Business Process Automation Capabilities. With Fiorano ESB, POSCO is successfully streamlining and automating internal processes companywide and also web enabling many of its operational support systems, improving service to its customers in the competitive Steel Manufacturing marketplace. Company Overview Estbish a l edin1968,Koea r -basedPOSCO is te h wol' rds lrest ag st eel manuf act ur er . Wit hanannualcr ude st eelpr oduct ioncapacit yof28mil l ion t ons andannualr evenues of$US8.6b,POSCO is consider edbyMor gan St anl eyt obe t he mostsust ainabl e companyint he st eelindust r y. The companymakes hot - andcol d-r ol l edst eelpr oduct s,whichitsel l st ot he aut oandship buil dingindust r ies. Subsidiar ies al soincl ude POSCO Engineer ing&Const r uct ionandPOSDATA. Business Problem POSCO is aggr essivel ydr ivingt he t r ansf or mat ionofSt eelManuf act ur ing pr ocesses t ost andar dize t he oper at ionsyst ems ateachSt eelmil l . This woul dl eadt oanincr ease incostbenef it s byminimizingr edundancyindat a andpr ogr am management . POSCO‘s Business andt echnicaldr iver s canbe summar izedas f ol l ows: • Cur r ent l yPOSCO‘s I Tinf r ast r uct ur e consist s of600comput er s of dif f er enthar dwar e,dif f er entOper at ingSyst ems. Some oft hese PCs t al kinBSCpr ot ocol s whil e ot her st al kinTCP/ I Ppr ot ocol ,r esul t ingin set t ingup of2paa rl l elnet wok rs wit hl it t l e scope ofco rss communicat ionbet weent hese PCs Solution Overview Profile Established in 1968, Korea-based POSCO is the world's largest steel manufacturer. With an annual crude steel production capacity of 28 million tons and annual revenues of $US8.6b, POSCO is considered by Morgan Stanley to be the most sustainable company in the steel industry. The company makes hot- and cold-rolled steel products, which it sells to the auto and ship building industries. Subsidiaries also include POSCO Engineering & Construction and POSDATA. Scenario EAI Messaging Infrastructure Business Process Automation Legacy Integration Fiorano Products Used ° Fiorano Enterprise Service Bus ° FioranoMQ • • • • • Addit ional l y,t hese comput er s ar e spr eadacr oss var ious geogr aphical l ocat ions inSout hKor eaatSeoul ,PohangandKwangYang. Al so,t he ingpoin-t-po t fc ic t ns atte h exist t o intiner a es bet weenvaio r us Applaio var ious St eelWor ks make monit or ing,maint enance andnew ic t ndevelpmen ydif f icut landt ime consuming Applaio o texr temel The cur r entI Tinf r ast r uct ur e is aver ycl osedsyst em t hatis ext r emel yr esist antt oanychanges inhar dwar e/ sof t war e conf igur at ionorupgr ade. This r esul t s inext r emel yhighmaint enance andupgr ade cost s Cur r enl, ty POSCO manual l ymonitr os al lte h Po rcess Compuer t ' s atit s l s. POSCO cur r ent l yneeds at eam of15engineer s at var ious St eelMil l ymonit or ingal lPr ocess Comput er sf orf aul t s. eachofit s sit e,manual ime bet weenprbem cr r ence andit s det ecio e Averg ae t o l ocu ' t nis quit high( appr oximat el y4hour s) Dat aexchange bet weenaPr ocess Comput er( PC)andaBusiness BC)is notoverar el r ver ,te h onyBa Compuer t ( iabe ll ink. Moeo l ckup andr ecover y( BRS)mechanism is acompl expr ocess ofanal yzing l y l ogs ateachoft he PC‘s andcompar ingwit ht hatofaBCt omanual f er ences. Al lLogs ar e st or edatnet wor kendpoint s andat det ectdif t imes t hese coul dbe mor et han200mil es awayf r om t he pl ace of r entsyst em pr ovides al mostnosuppor t det ect ionofpr obl em. The cur f orr emot e accessingofl ogs andevent sf orr emot e debugging POSCO cur r ent l yhas nodisast err ecover ysyst em impl ement ed acr oss t he ent ir e St eelWor ks. I ncase t he Business Comput er ‘s at KwangYanggodown,t her e is nopr ocess inpl ace t oensur et hatt he lt he PC‘s and. This Business Comput eratPohangt akes cont r olofal l yateachoft he 200PCs t hatar e swit chhas t obe made manual f er entgeogr aphicall ocat ions acr oss Sout hKor ea dist r ibut edatdif Current Architecture Topology POSCO‘s cur r entI Tinf r ast r uct ur e consist s oft hr ee maj oringr edient s: POSPIA at Seoul POSCO‘s cor e digit almanagementsyst em is cal l edPOSPI A. The POSPI A syst em is l ocat edinSeoul( Boon-dangdat acent er ) . I tis composedofERP ise Resouc lnning, ) SCP( yChainPa lnning)Ener t pr ( Ener t pr re Pa Suppl ise syst ems,Dat aWar ehousing,et c. The ERPsyst em t akes car e ofOr der lal l ot ment ,ATPCheck,andPr ogr ess management . The SCPt akes Ent r y,Mil car e ofPr ocess pl an,Pr ogr ess managementandPr oduct ionManagement . oms Saes l andPo rducio a ,Orer d managemen, The SCPasoper l fr t npln t t n,andCostmanagemen. t Quait lyDesign,ShipmentDistib r uio Figur e 2.3POSPI ADat aFl ow Pohang Works Fuj it su‘s FACOM mainf r ame is usedt ohouse t he cur r entpr oduct ion managementHost( Business Comput erorB/ C)atPohang. Ther e is one l e machine andone hotstn a dbybackup. The Hostconrl tos st onin eel manuf act ur ingpr ocesses andital soser ves as t he f ocalpointf orot her comput er s( Pr ocess Comput er s anddist r ibut es ser ver s)t ot r ansmit / r eceive dat at o/ f r om t he POSPI A. The FACOM Hostpr ovides connect ionint er f aces inFNA( BSC/ HDLC)and TCP/ I Pmode. Pieces ofequipmentconnect edt ot he HostinFNAar e P/ Cs ( 65equipment ) ,handy,andt er minal s. Pieces ofequipmentcommunicat e wit ht he HostinTCP/ I Par e P/ Cs ( 136equipment ) ,LabelPr int erser ver s( 11 equipment ) ,dist r ibut edser ver s( 37equipment ) ,andper sonalcomput er s. Figur e 2.5Cur r entSyst ems inPohangWor k KwangYang Works I BM mainf r ame is usedt ohouse t he cur r entpr oduct ionmanagementHost ( B/ C)atKwangyang. Ther e is one onl ine machine andone hotst andby backup. The Hostcont r ol s st eelmanuf act ur ingpr ocesses andital soser ves as t he f ocalpointf orot hercomput er s( Pr ocess Comput er s anddist r ibut es ser ver s)t ot r ansmit / r eceive dat at o/ f r om t he POSPI A. The I BM Hostpr ovides connect ionint er f aces inSNA( BSC/ SDLC)andTCP/ I P mode. Pieces ofequipmentconnect edt ot he HostinSNAar e Pr ocess Comput er s( P/ C)( 57equipment ) ,handy,andt er minal s. Pieces of equipmentcommunicat e wit ht he HostinTCP/ I Par e P/ Cs ( 184equipment ) , LabelPr int er s( 53equipment ) ,dist r ibut edser ver s( 15equipment ) ,and per sonalcomput er s( 110equipment ) . Figur e 2.6Cur r entSyst ems inKwangyangWor ks The exist ingt opol ogyincl udes anumberofdispar at e pl at f or ms and ic t ns attese h hee lc t ns as descib r edinte o Applaio tr o aio h tbe a l belw: Steel Works Pohang Kwangyang Hardware Fuj it suFACOM SuperDome Hp r p8400 HPr p7410 I BM Mainf r ame SuperDome HPr p8400 HPr p7410 OS MSP/ EX I nf o. Notr equir ed HP-UX 11.11i HP-UX 11.11i OS390V2.7 I nf o. Notr equir ed HP-UX 11.11i HP-UX 11.11i Protocol BSC,TCP/ I P,HDLC TCP/ I P TCP/ I P TCP/ I P BSC,TCP/ I P,HDLC TCP/ I P TCP/ I P TCP/ I P I twas becomingincr easingl ydif f icul tf orPOSCO t oexchange dat abet ween ems andApplaio ic t ns due t o t hese l egacyApplaio ic t ns andoh ternew Syst f er entpr ot ocol s. dif System Requirements The POSCO Ar chit ect ur e gr oup hadbeenaskedt odesignanew syst em t hat lr esol ve t he cur r entBusiness andTechnicalPr obl ems andal sopr ovide wil exibilyt oemerin retr equir t The Arh ecue t he f l it oadaptt g gmak emens. c it tr l owingr equir ement sf ort he new syst em: t eam came up wit ht he f ol • • • • • • Ability to integrate current Applications running on disparate hardware and varied operating systems- POSCO‘s I T inf r ast r uct ur e is spr eadover400mil es wit h600comput er s ofvar ied har dwar e,OSandevencommunicat ionpr ot ocol s. 200PC‘s ( Pr ocess r spr eadoverPohang&KwangYang- get t ingl ive Compuer t s)ae inf or mat ionf r om st eelmanuf act ur ingmachines. Wit ht he new lt hese PCs needt osendr eal -t ime inf or mat iont oBC inf r ast r uct ur e al ( Business Comput er ) ,whichis anI BM Mainf r ame. Improve Quality and Operational processes - POSCO of f icial l y l aunchedit s SixSigmacampaignbyhod lingte h 'ixS S igmaFir st Wave LaunchCer emony'onMay22002. Thr ought he SixSigma l yandscient if ical l ymaximize campaign,itpl ans t ost at ist ical companywor kqual it ybybasingt he endeavoront he inf r ast r uct ur e a l edinte I Po rvidingapprpr t t hatwas estbish h fst ir phase ofP. o iae f icul tas t her e wer e inf or mat iont oper f or m SixSigmat asks was dif a ofdaaa h quait lyandopert aion over lps t mongsyst ems andte anal ysis dat awas notaccur at e. I naddit iont ot his,Compl exdat a f icul t . Forachievingt his makes per f or mingqual it yanal ysis dif j t e,estbish a l ingunif iedweb-basedopenopert aionsyst obeciv ems on t op oft he new inf r ast r uct ur e becomes highl yimpor t antf orPOSCO. The new inf r ast r uct ur e shoul dal sohel p POSCO move t owar ds mor e obe abe eaiz ulbenefs it ofnew t echnoo lgies — open-syst ems“t lt or le fl Ability to manage dif f erent Data Formats - The POSPI Aand POSCO‘s Shop Fl oorSyst ems consistofappr oximat el y20t ypes of r ent l y,t her e ar e about110ser ver s wit h syst em pl at f or ms. Cur var ious Oper at ingSyst ems andDat abases. Business I nf or mat ionis st or edinvar ious f or mat s. Forinst ance,Cast ingknow-how st andar ds ar e managedinl ogicandf il ef or matatPohangandl ogicandina l inginspect ionst andar ds r eside t abl ef or matatKwangyang. Col dRol inf il e andl ogicf or matatPohangandl ogicint abl ef or matatCol d l ofcitt Rol ingPo rcesses atKwangyang. The new syst em neededt a ilae inf or mat ionshar ingacr oss suchsyst ems. Ability to Automate Business Processes spanning geographical ll ocat ions inPohang, boundaries - POSCO‘s has mul t ipl e Mil KwangyangandSeoulwher e St eelis pr oduced. The exist ingsyst em consist s ofanI BM hostBusiness Comput ereachatKwangyangand l er s att he shop f l oor , Pohang. The Pr ogr ammabl e LogicCont r ol monit ort he manuf act ur ingpr ocesses andar e connect edt ot he Pr ocess Comput er s whichincl udes l egacysyst ems l ike Mel cof r om Mit subishi,Hit achi machines et candmor e moder ncomput er s. For l ingsequence change pr ocess t akes pl ace in inst ance,POSCO‘s Rol l ingdepar t mentatPohangandinPr ocess Shipping HotRol depar t ment( underPr oduct ionCont r ol )inKwangyang. The new em inrstu tr shoudh l ave te rnsf erdaaa syst fa rcue h abilyt it ota t tr eal t ime f r om one l ocat iont oot herinasecur e manner . Ability to Administer and Monitor Applications at Real-time r oroccur s,itis cur r ent l yver ydif f icul tt oquickl y Wheneveraner • • • • ident if ywher et hater r orhas occur r edandcor r ectit . Again,t he l ack fexibilyo te cur r entinrstu tr genert aes dely a s andtu ofl it fh fa rcue hs evenues. I ncase ofa filr e l ostr ue,numeru o s manualconrl to andr t r ansmissionpr ocesses have t obe act ionedwit hinandbet weeneach applaio ic t n. Ability to integrate Legacy systems withthe best-of -breed l er s( PLC‘s)at new Applications - The Pr ogr ammabl e LogicCont r ol t he shop f l oormonit ort he manuf act ur ingpr ocesses ar e connect edt o t he Pr ocess Comput er st hatincl udes l egacysyst ems l ike Mel cof r om Mit subishi,Hit achi machines,whichdonotsuppor tTCP/ I P. I nst ead t heyuse oh tereg l acyprtc oo os ll ike BSC,HDLCandSDLC. Ability to respond to Business Changes Quickly and more f iciently- The exist ingpoint -t o-pointint er f aces bet weenvar ious ef ic t ns atSeel t Wok Applaio rs make mainen t ance andnew devel opment s dif f icul tandt ime consuming. The compl exit y, unmanageabilya it ndcostofpoin-t-po t o intapplaio ic t ninegaio t rt nae r huge. POSCO was l ookingf oranEAIPl at f or mt hatcoul dpr ovide capabilies it offst a err esponsiveness t oBusiness Po rcess Changes. ForExampl e inPOSCO‘s Sal es Aut omat ionSyst em t her e is an at t r ibue t cal l ed” init ialcost ‘. The defut a lvau le is 10 ,00wonunil t May 31,200223: 59: 59andt he def aul tval ue wil lbe changedt o 10, 000wonf r om J une 1,200200: 00: 00. Thent he usershoul dbe abl et osett he condit ionsot hatexist ingadapt erwil lt ake car e of dat aup t ot imest amp ofMay31,200223: 59: 59andst ar tanew adapt erwit ht he change att he sett ime ( J une 1,200200: 00: 00)so t hatmessages r eceivedaf t ert he sett ime wil lbe pr ocessedbyt he new adapt er . Implement Disaster Recovery System œ I mpl ement ingaDisast er Recover ySyst em,as apar toft he new ar chit ect ur e is amaj orst ep t owar ds ensur ingcont inuous manuf act ur ingandt oensur e cont inuous dat af l ow andmonit or ing. Givent he highvol ume ofinf or mat iont o pr ocess ever yday,eachf l ow has aver yspecif icschedul et ime f or inghighavailb a ilyo te whoe l inegaio t rt n pr ocessing,r equir it fh inf r ast r uct ur e. I fapr ocess is del ayedbymor et han15minut es,t he ent ir e inomaio fr t nchainis dely a ed,genert aingdely a s indel iver yof d s andtu o saes orer h s lst l fr o POSCO. Ability to integrate withPartner Applications - POSCO par t ner s f icient l y. Those wit hmanycompanies inor dert or unit s business ef companies incl ude r aw mat er ialpr ovider s,f inishedst eelpr oduct manuf act ur er s,t r anspor t at ionpr ovider s,et c. MostofPOSCO‘s ter e rn ic t ns andplt afr ht parn s companies wer u ningApplaio oms ta wer e dif f er entt hant he ones beingusedf ormanagingPOSCO‘s int er nalpr ocesses. The new syst em is envisagedt opr ovide r eal -t ime conneciv t it ybet weentese h Applaio ic t ns fr o havingfl ulvisibilyo it fal l t r ansact ions t hatf l ow bet weent hem. The Solution Af t err esear chingpossibl e sol ut ions t osat isf yt he r equir ement s,t he POSCO Ar chit ect ur e Gr oup r ecommendedimpl ement ingFior anoESB t opr ovide a ser vice-basedar chit ect ur e connect ingt he var iedas sof t war e andhar dwar e pl at f or ms as ment ionedabove. Fiorn a oESB is adistib r uedS t eric v es It negaio rt nPafr ltom ta h tsimplies if t he composit ion,depl oyment ,modif icat ionanddebuggingofbusiness lt ns pac thedtg o eter hseverl a poin-prd t o ucs, t pr ocesses. Unik l e souio h wit Fior anoESB is adist r ibut edpl at f or m basedont he superpeert echnol ogy wit hal ayer edar chit ect ur e compr ising: • • • • • J MSMessagingSer ver- Fior anoMQ Fior anoEnt er pr ise Ser ver Fior anoPeerSer ver s ManagementTool s Adapt er s Fir standf or emost ,t ot ackl et he pr obl em ofint egr at ingLegacySyst ems ( wit hnon-TCP/ I P)pr ot ocol )wit ht he new br eedofPC‘s,aGat ewayser ver was designedt odot he conver sionf r om TCP/ I Pt ot he B/ Cpr ot ocolt hatis lt he l egacysyst ems wer e connect edwit h under st oodbyl egacysyst ems. Al t he gat ewayser vert hatcanbe connect edt oanyot hersyst em suchas HP UX orWindows t hatunder st andTCP/ I P . Mul t ipl e DCPAdapt er s wer e inst al l ed ont he gat ewayser verandeachoft hese have BSCpr ot ocolpr ogr am downl oadedint hem. These adapt er s cant hent al kwit ht he l egacysyst ems. Fior anoESB canr unonbot hAI X andWindows machines andt he dat aar e sentacr oss t ol egacysyst ems t hr oughBSCcar ds. I nt egr at ionoft hese t l eneckt hatexist ing l egacysyst ems wit ht he new PC‘s was t he biggestbot inf r ast r uct ur e pr oduct s( I BM MQSer ies,WebSpher eI nt egr at or )wer e not abl et opr ovide. Fior anoESB def ines anew br eedofopen-endedent er pr ise int egr at ion rstu tr Fioa rnoESB hel inks individualener t pr ike POSCO, inf a rcue. ps l ises l f iciencyacr oss t he suppl ychain,al l owing t oget herf orext endedpr ocess ef exibilya a ilyt a l hangingbusiness t hem moe rf l it ndadaptb it orpidyc r equir ement s. Beingapur ej avabasedimpl ement at ional ongwit hr unt ime ibaies tera l rr fr o oh lnguages suchas C,C++,VisualBasicmakes itrnwit u h lt he syst ems. al mostal Fior anoESB al sopr ovidedPOSCO wit hacompr ehensive setofManagement andMonit or ingTool s. Wit hFior anoESB‘s Business Pr ocess Management lst Capabilies, it POSCO‘s Business andTechnicalAnay s cannow quickl y compose,devel op,t estanddepl oyBusiness Pr ocesses. I naddit ion,Fior ano l gCapabilies h ESB‘s Monitr oingandEventHandin it prv o idedPOSCO wit Gr aphicalTool st oinvest igat et he or iginoft he pr obl em andt hent ake r ect ive act ion. This notonl yhel pedinminimizingt he er r or s butal so cor r educedt he del ays inpr obl em r esol ut ions. Fior anoESB pr ovideda cent r al izedsyst em f orRealTime monit or ing,debuggingandadminist r at ion f ort he whol e syst em f r om ar emot el ocat ion. Fiorn a oESB prv o ides mut lipl e Fil e( Fil e Reader ,Fil e Wr it erAdapt er s)and Dat abase Adapt er s( Or acl e,DB2,SQLSer veret c.)t ohandl e awide r ange of dat aandf il ef or mat s. The Fior anoPr e-Buil tAdapt er s ext r actt he Met aDat a inf or mat ionf r om t he Sour ce andsendt he dat at ot he Tar getDat aSour ce t y gvaio r us Business Rues, rnsfr omaio l aio af erapplin l ta t ns andvaid t ns. l edt he Fior anoESB al socomes al ongwit havisualdr aganddr op t oolcal f er entXMLf or mat s. The use of Fior anoMappert hatcanbe usedt omap dif Fior anoAdapt er s andt he Mappingt oolhel pedPOSCO save pr ecious t ime andr esour ces,whichwoul dot her wise be r equir edf orpr ogr ammingt hese f er entcompl exBusiness Rul es andval idat ions f oraut omat ingt he dif Manuf act ur ingBusiness Pr ocesses. Figur e 3.1Pr oposedSyst ems usingFior anoESB Fior anoESB pr ovidedPOSCO wit hmul t ipl el evel s off ail oversuppor t( ver y impor t antf oradisast err ecover ysyst em) . These ar e: J MSFai l over :Mul t ipl eJ MSbus‘s canbe st ar t edondif f er entmachines and t he Fior anoEnt er pr ise Ser ver( FES)andFior anoPeerSer ver s( FPS‘s)canbe f er entor derofpr ior it y. I n conf igur edt oconnectt ot hese J MSBuses wit hdif lt he Fior anoESB ser ver s ont he case off ail ur e ofanyoft he J MSbus,al net wor kgetaut omat ical l yconnect edt ot he nextavail abl eJ MSbus as per t he def inedpr ior it y. Dur ingt his migr at ionf r om one J MSt oanot her ,t hese ser ver s st or e dat a,t her eby,ensur ingnodat al oss. Ene tr pr i seSer verFai l over :TwoEnt er pr ise Ser ver s canbe st ar t ed simul tn a eousl yt oenabe l hotfilv a o ersuppot r atte h Ener t pr ise l evel . One of t he FESact s as apr imar yone andt he ot herone as secondar y. The Secondar yFESkeeps aconst antvigilandwhenevert he pr imar yFESget s lt he t ime disconnect edf r om t he net wor k,t he secondar yFESt akes over . Til t he pr imar yFESis up,itkeeps synchr onizingt he secondar yFESwit ht he lt he peerser ver sr unningont he net wor kwil l l at estinf or mat ion. Al aut omat ical l yswit cht osecondar yFESincase ofpr imar yFESf ail ur e. Ser vc ieLevelFai l over :I nanent er pr ise wide net wor ksuchas POSCO‘s,itis quit e possibl et hatt he Fior anoPeerSer ver( FPS)goes downorget s t hte wok lte v es rn disconnecedwit h net r. Al h Seric u ningonta h tpat ricua lr l yl aunchedonsome al t er nat e FPS,ifdesir edby FPScant henbe aut omat ical te h user . Fiorn a oESB prv o idedPOSCO wit hte h abilyt it odynamical l ymake tese h changes andsynchr onize wit ht he exist ingBusiness Pr ocesses. Fior ano ESB‘s componentmodelpr ovidedPOSCO wit hadist r ibut ed,int er net enabl ednet wor kandal soal l ows ( t hr ought he aidofvisualt ool s)t he f icientsynt hesis anddepl oymentofent er pr ise business pr ocesses by ef s andener ise manager l e,whil r pr oga rmmer t pr s aik e suppot ringahigh-degee exibilyœ ofr eusabilya it ndf l it as summaiz r edbelw o . POSCO‘ s Enterpri se Users POSCO‘s Business User POSCO‘s ComponentPr ogr ammer Benef i ts wi thFi orano ESB Spr eadsheetl ike simpl icit y Real -t ime Modif icat ions oft he business pr ocess Ext endpr ocesses wit hnew component s whenr equir ed Focus onI nt r a-componentl evel det ail s( t asks,f unct ions) Test ingandQAatt he component l evelassumingst andar ds-based int er f aces POSCO‘s Business Pr ocess Devel oper Focus onI nt er -componentl evel assembl ydet ail s Remot e composit ionoft he business pr ocess Buil t -inSecur it yatt he component lsecur it y l evelenhances over al Remot el aunch,monit or ingand debuggingofbusiness pr ocess