SIMATIC IT Industry Libraries Hybrid

for Process
Functional Overview

www.siemens.com

June 2013

SIMATIC IT Industry Libraries Hybrid for Process issued by: Siemens. © Siemens AG 2013. All rights reserved.
Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 2

Contents

1 Introduction ................................................................................ 4

1.1 MES and Production Modeling ........................................... 4

1.2 Standards and Compliance ................................................ 5

1.2.1 ISA-95 Compliance ............................................................. 5

2 Why focus on MES and Production Modeling? .............................. 6

2.1 Business issues .................................................................. 6

2.2 Production issues ............................................................... 7

2.3 IT issues ............................................................................ 8

3 How you can succeed .................................................................. 9

3.1 The SIMATIC IT model for Process Industry ......................... 9

3.2 Business Benefits ............................................................. 10

3.3 Production Benefits ......................................................... 11

3.4 IT Benefits ....................................................................... 11

4 SIMATIC IT Industry Libraries Hybrid for Process ......................... 12

4.1 Factory in a Box Primary ......................................................... 12

4.2 Factory in a Box Secondary ..................................................... 13

4.3 Integrated Quality .................................................................. 14

4.4 Logistics ................................................................................. 15

4.5 Data Concentrator/Data Coordinator Collections (DCC-

DCO) ............................................................................................ 15

4.5.1 The Data Concentrator (DCC) ................................................. 16

4.5.2 The Data Coordinator (DCO) .................................................. 16

5 Major features in version 3.3 ..................................................... 17

5.1 What’s New in Industry Libraries Hybrid for Process v 3.3 ........ 17

5.2 SIMATIC IT ILH Primary .......................................................... 17

5.3 SIMATIC IT ILH Secondary ...................................................... 17

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 3

5.4 SIMATIC IT ILH Integrated Quality .......................................... 18

5.5 SIMATIC IT ILH Logistics * ...................................................... 19

5.6 SIMATIC IT ILH DCC-DCO Secondary * .................................... 20

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 4

1 Introduction

1.1 MES and Production Modeling

In the early Nineties, industries acknowledged the need for a layer to integrate and link Business Systems with
Control Systems. The term Manufacturing Execution Systems (MES) has been used from the start to specify
all those functions and products that satisfy this need.
Initially, MES indicated a “gray” area that was a hodgepodge of almost every application or product that could
not be clearly assigned to either the Business System or the Control System layer. Most of these products were
spinoffs of applications developed by a System Integrator for a particular Customer and were generally focused
on a very specific area (i.e. scheduling, laboratory, quality, tracking…).
After some time, international organizations addressed the need for a clearer definition of MES: MESA (Manu-
facturing Enterprise Solutions Association) and, as a consequence, ISA (Instrumentation System and Automa-
tion Society) later developed models that describe these levels and seek to standardize them.

Under the pressure of new business-driving forces that have been emerging in recent decades, Manufacturing
Plants continue to play a major role. The globalization of both companies and production processes makes it
necessary to create new models. Manufacturing is not a process that can be completed by a single self-enclosed
entity, but extends beyond the bounds of the Plant, the Country and the Enterprise.
Therefore, MES cannot act simply as an interface between Business and Process layers, but requires a substan-
tial number of functions that are crucial to a Company’s success. Rather than remaining distinct from one an-
other, connected solely by a data exchange layer, these functions need to be coordinated, in adherence to the
Business and Production strategy.

ISA-95 documents point this out very clearly, describing the MES process in terms of both data and interaction
between functions (e.g. Order Dispatching, Resource Management).
The result is a new approach to MES, based on an architecture that allows describing Business Processes that
orchestrate functionalities provided by a set of specialized and affordable Components.
At the same time, this orchestration must also involve the Automation and Control level, thereby making both
MES and Control part of the same Collaborative Production Management system.

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1.2 Standards and Compliance

1.2.1 ISA-95 Compliance

ISA-95 is acknowledged as the most authoritative standard for MES applications. Not only Market Analysts such
as AMR (www.amrresearch.com) and ARC (www.arcweb.com) confirm this, but also several major vendors
adopt this standard. In addition to Siemens, we can find, for example, SAP and Microsoft.

Siemens works in close conjunction with ISA and was the very first MES vendor to offer a comprehensive prod-
uct implementing the ISA-95 standard. This translates into standardized terminology, concepts and models for
integrating manufacturing operations functions with enterprise functions. Such standardization is achieved
with ISA-95, which defines the functional view of an enterprise, allowing a simple generic model of work activi-
ties to be applied to the main areas of manufacturing. As a member of the ISA-95 Committee, Siemens actively
contributes to the further development of this standard.

Complying with ISA-95 makes it possible to reap some important benefits: in particular, for what concerns de-
fining the hierarchical model of the MES solution, which simplifies developing solutions that are both standard
yet flexible, while still satisfying customer requirements in full.

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2 Why focus on MES and Production Modeling?

On a daily basis, a variety of figures in charge of different activities face problems that involve manufactur-
ing systems. Implementing MES and deploying the right production model can provide a solution to many
of these issues. In broad outline, the problems encountered concern: S

 Business
 Production
 IT

2.1 Business issues

Do you want to increase the overall efficiency of your supply chain?
Supply-chain efficiency is strongly affected by how the Business level (ERP) and the Shop Floor (Control)
interact. MES represents the go-between, which, when streamlined and efficient, contributes to a better
Supply Chain.

Is your system able to react quickly to new conditions and new market requirements?
In today’s world of manufacturing, the ability to adapt to new operational requirements (i.e. changes in
product specifications, quality procedures…) and environmental conditions (i.e. introduction of new
standards…) is paramount to success. If your system is ready to meet these challenges, the reward may be
a significant increase in your competitiveness, as well as impressive savings in terms of costs.

Is your production process standardized across all plants?

Guaranteeing uniform, consistent production procedures is a key issue in today's business. If this is lacking,
then the result may be uneven quality of your product from one facility to another. Control System and
Business System cannot solve the problem, as a structured and modeled environment is required in order
to seamlessly coordinate the production process, also in different contexts (e.g. different hardware and
software installation bases).

Are you ready for new regulations?

Some established standards and regulations, such as FDA, already exist to guarantee high-quality prod-
ucts. However, new regulations, as well as the need for exhaustive material traceability, are affecting
manufacturing procedures substantially. MES can help you achieve compliancy with these regulations and
maintain full accountability of materials.

Would you like your business to be more customer-oriented?

Standard monolithic applications often represent a barrier to implementing an efficient system that can
adapt and satisfy ever-changing requirements from both the customer and the market. In view of the
growing demands posed by Customers, MES can make your system much more flexible and adaptable.

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2.2 Production issues

Do you handle reworks and scraps properly? Do you track how your materials are used with preci-
sion?
Typically, reworks and scraps cannot be handled by control systems. Without appropriate management,
excessive waste or uncontrolled material tracking can also affect the quality of your final product. In addi-
tion, overall material tracking throughout the production process is now a crucial factor for both account-
ing and the correct evaluation of production costs. S

Do you need to increase visibility of your production process? Is your system able to provide Produc-
tion-related KPIs and advanced reporting?
To fully comprehend how your plant is performing, you need a system that can generate production re-
porting correlating process-control specific data with production-related data (i.e. order number, lots,
personnel, materials…) to facilitate troubleshooting and analyzing performance problems. MES can
heighten visibility in the production process, creating the right conditions to promote improvement and
increase your manufacturing system’s efficiency.

Do you need to raise your level of quality? Are you able to pinpoint contaminated lots or out-of-spec
finished-goods lots? Are you able to backtrack your production with accuracy?
If not, you might be unable to address specific issues regarding the quality of your product. You may also
be unable to respond to customer complaints appropriately or organize product recalls promptly. An effi-
cient MES system can provide complete genealogy, being able to track materials throughout the entire
production process. It also follows all material transformations with precision until the final product is
produced and delivered to the final customer.

Does your system react efficiently to production problems? Do you re-schedule your plant activities
properly?
What if something goes wrong on the shop floor? Efficient management of failures and downtimes is a
must. Often, several systems need to be involved in order to solve the problem (maintenance must be
informed, rescheduling is necessary, certain people must be notified as soon as possible…). Poor coordina-
tion leads to using resources in an ineffective manner, ultimately raising your production costs.

Is your ERP System working with the Manufacturing Operations System efficiently?
To optimize Supply Chain efficiency, the Business Logistic System must be informed in real-time as to what
is happening on the Shop Floor, especially in terms of Production Performance. This is especially useful in
terms of planning, as well as both material and warehouse management.

Is your manufacturing system totally integrated?

Total integration between Process Control, MES and ERP is essential in today's business. The manufacturing
system consists in the joint efforts of a variety of functions. Good integration can make a difference for
attaining top-level efficiency: on the contrary, poor integration can hinder your efforts to improve plant
performance.

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2.3 IT issues
Is your System properly integrated and synchronized? Are there so many links between applications
that communication is difficult? Are your IT maintenance costs too high?
A myriad of links between your Software Packages greatly increases the complexity of the manufacturing
system. In turn, costs for IT maintenance and program modification become staggering. This is mainly due
to the lack of coordination and flexibility of the majority of manufacturing applications. The modeling
approach can effectively simplify integration and actively coordinate the interaction and the flow of infor-
mation between different applications on site.

Is implementation too expensive? Do you frequently assess projects as falling in the "high-risk" cate-
gory?
Being able to employ reusable solutions creates the conditions for streamlining and speeding up project
implementations. Total ownership costs can be cut dramatically, thanks to efficient software reusability.

Does sharing your know-how represent an obstacle? Would you like to re-use your expertise and
your software effortlessly?
Efficient reusability of software is key to effective cost saving. Being able to "code" the expertise permits
the rapid transfer of know-how between users, which is usually not feasible with standard applications.
Without a modeling environment to help you define business procedures, focusing on the production pro-
cess rather than specific IT issues, the understanding of complex manufacturing applications is rather
difficult, making it virtually impossible to modify or reutilize code.

Do you need a more streamlined environment for monitoring and troubleshooting?

Typically, a production system is a complex integration of software applications and physical devices. Pin-
pointing problems and debugging are serious issues that require a great deal of effort and ultimately cost
money. If you are able to model and run programs and business procedures from a single environment
involving several systems, then extended monitoring and troubleshooting become more than just a possi-
bility.

Is it difficult for you to maintain your team’s technological skills at top level? Are the costs to train
your staff in line with state-of-the-art technology excessive?
Applications are very often numerous and customized to satisfy specific needs. As a result, frequently, the
person with the most know-how is used to develop and maintain these applications. Such competence is
very difficult to maintain, as well as very expensive. By adopting SIMATIC IT, which covers all functionali-
ties in an integrated and homogenous environment, complex manufacturing systems can be implemented
with ease, making the tasks involved viable even for those users who possess normal skills.

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 9

3 How you can succeed

3.1 The SIMATIC IT model for Process Industry

The challenges in today's manufacturing environments are becoming more and more exacting and manu-
facturers need from their supplier solutions that provide tangible benefits with quantifiable and quick
return on investment. To increase competitiveness, manufacturers need to simultaneously reduce time-to-
market, increase process visibility and production flexibility, optimize forecasting and scheduling, and
reduce scrap, stock levels and downtimes; all while ensuring optimal quality and production efficiency
across all global facilities.
In an enterprise IT architecture, this would translate in enabling communication and integration between
the key IT components that are contributing to bringing products successfully to the market.

In order to rationalize/ speed up processes, the product design / ideation data, need to be seamlessly trans-
ferred to the actual R&D environments, where formulation and formulation testing is typically being exe-
cuted
The R&D process is the critical link between Product ideation and manufacturing. It’s where ideas become
industrialized reality… true speed comes than when also these data, are seamlessly transferred to the
manufacturing floor for the actual execution of the production. Real-time capabilities and supply chain
efficiency, come from interoperability with the financial/ administration software, managing customer
orders and transferring these back to manufacturing or R&D environments
In parallel, also the production floor needs to be ideally equipped and organized, in order to be able to
produce in an efficient way, avoiding unforeseen problems with equipment capacity, energy use, etc.
Therefore, our digital factory / Plant lifecycle management part of the portfolio enables virtual testing and
commissioning of plants and their equipment, up front delivering the needed configurations for the auto-
mation layer, which in turn communicates with the manufacturing execution level.

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 10

All these interactions, managed by the Siemens Industrial Software portfolio, enable integration of the
product and production lifecycles – resulting in faster time-to market.
In order to increase the efficiency of the manufacturing plants in a way that is
• Fully integrated with the ERP
• Compatible with new products introduced from R&D
• Integrated with legacy Manual, DCS, PLC and Batch Managed Processes
• Compliant with legal Quality requirements
• Complete with the reporting and analysis tools required to support operations staff
Siemens has organized its Process Portfolio for Manufacturing Execution into a plug-and-play Factory-in-a-
box that can be rolled out and maintained with a very low TCO.
Fortunately each vertical market in the process sector share common characteristics that enable Siemens
to address them with a single solution and value proposition:

• Raw Material receipt

• Storage in Tanks or Warehouse
• Primary Process, production phase where Raw Materials (RM) are transformed into Semi-Finished-
Goods (called also Intermediated Goods)
• Intermediate Tank or Warehouse storage
• Secondary Process, production phase where Semi-Finished-Goods are transformed into Finished Goods
(FG) ready to be shipped to the customer. This phase is typically further divided in at least 3 sub-
phases: Filling – Packaging – Palletizing
• Final Tank or Warehouse storage
• Shipping

The Factory-in-a-Box is highly modular and scalable and can be deployed with a stepwise approach. Fur-
thermore, the Factory-in-a-box solution is structured in main sub-niches:
• Primary – called Primary-in-a-box – to support the primary production
• Secondary – called Secondary-in-a-box - – to support secondary processes (filling, packaging, palletiz-
ing)
• Integrated Quality to support the quality management
• Logistics to support the in-bound logistic
They can be used in tight combination for moving wall-to-wall inside a customer or only in specific area
depending on the customer requirements.
Each sub-niche can be enriched and completed with the Data Concentrator/Coordinator – called DCC/DCO -
to support a standardized and reliable message-based communication interface between the MES and the
Automation Layer with dedicated components for Primary and Secondary

3.2 Business Benefits

SIMATIC IT Production Suite fills the gap between Business Logistic Systems (typically, ERPs) and Control
Systems, providing the conditions for increasing overall supply-chain efficiency. The unique approach of
SIMATIC IT allows manufacturing systems to have a native flexibility that gives users the possibility to easi-
ly adapt and modify the business process to new requirements and business drivers.

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 11

• SIMATIC IT Production Suite allows manufacturers to model their own business to be much more cus-
tomer-oriented and ready to satisfy any on-the-fly requirements from the market.
• SIMATIC IT Production Suite has also been designed to facilitate application roll-out to several plants,
thus being extremely cost-effective in multi-site contexts.
• SIMATIC IT Production Suite effectively helps users to comply with existing regulations.

3.3 Production Benefits

SIMATIC IT Production Suite offers a set of modules able to cover the MES core requirements in any manu-
facturing context. By modeling and defining production procedures, SIMATIC IT Production Suite effective-
ly increases visibility on the entire production process.
• Tracking and tracing of materials can be configured in order to match the actual process with preci-
sion.
• Having a clear view of material usage makes it possible to reduce stock, analyze production costs in
greater detail and manage scraps and reworks in an efficient manner.
• SIMATIC IT Production Suite can rebuild the complete material genealogy (both backward and for-
ward).
• SIMATIC IT coordinates and integrates a variety of systems, each with its own scope, thereby providing
true added value to the production system as a whole.

3.4 IT Benefits
The basic approach of SIMATIC IT makes it possible to model business rules in a graphical way so as to
represent the interactions and the expected flow of information among different software components
(including those that are not part of SIMATIC IT Production Suite). SIMATIC IT Libraries, classes and inher-
itance mechanisms create the conditions for an effortless rollout and reutilization of SIMATIC IT Production
Suite applications.
SIMATIC IT Production Suite permits users to focus on process issues, rather than IT issues.
In SIMATIC IT Production Suite, technological aspects are transparent to the user, who, as a result, requires
fewer skills than what is normally required to develop standard MES implementations.
Costs for maintenance and application modification are pared to the bone.
Siemens partners can create their own SIMATIC IT Libraries, coding their own expertise and making it easi-
ly reusable, thus dramatically reducing the average development time for MES projects.

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 12

4 SIMATIC IT Industry Libraries Hybrid for Process

4.1 Factory in a Box Primary

The Factory in a Box Primary is a collection of several Hybrid-Industry Libraries (ILH) and Basic-Framework
Libraries (FRM).
These have been brought together and partially pre-configured in order to cover the most common func-
tional requirements of the primary production phase.
Primary Collection provides libraries dedicated to different scopes, such as:
 ERP integration for order and master data
 Master Data management, BOM, Routing
 Product and production validation
 Production Order for intermediate material
 Sub Order and Batch management
 Control Recipe management – EBS
 Product Production and Consumption declaration
 Material declaration, Material consumption
 Automation Integration (DCC-DCO and SIMATIC Batch)
 Label Management
 Container Management

Here is a complete list of the included libraries:

• Production Order Handling Library (ILH-POH) handles production orders at MES level. The library fo-
cuses on the engineering side of orders and entries management, and it addresses especially a super-
visor user, who engineers the production and monitors the runtime.
• Process Management Library (ILH-PRO) handles each step of production, from the order initialization
to the completion. The library focuses on the runtime phase of a production step, managing activities
such as order dispatch, material declaration and consumption, download of parameters to Control
Level, and so on.
• Line Management Library (ILH-LMG) allows the creation and maintenance of virtual lines.
• Recipe Management Library (ILH-RCM) handles recipe management for production plants.
• Lot Information Library (FRM-LIN) allows the user to view Material Lots and their Genealogy Links
• Material Management Library (FRM-MTL) handles the materials in a production system.
• Pallet Management Library (ILH-PAL) permits managing pallets and movable containers, that are typi-
cally reusable pallets (that can be empty or with one or more lots inside) and are used to move
amounts of material during the production phase.
• Labeling Management Library (ILH-LBL) provides the basic functionalities to create label data and to
configure label templates.
• Corrective Action Management Library (CIL-CAM) allows managing Corrective Actions (CA) which are
actions that can be performed during run time plant functioning to recover, for instance, to critical
situations.
• Electronic Work Instruction Library (CIL-EWI) allows the operator to manage Electronic Work Instruc-
tions which are forms containing a list of instructions that must be read to understand an operation
that has to be done and has to be filled by the operator to check important production variables.

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 13

• Tank Farm Management Library (ILH-TFM) manages the movements of materials between tanks in a
plant and allows external applications (e.g. other libraries) to search for material within the tanks or
for tanks where they can place material.
• Communication Management Library (ILH-CMM) allows messages to be exchanged between external
systems and Manufacturing Execution System (MES) applications. A typical example of an external
system which needs to send/receive messages to/from MES is the Control Layer. Examples of MES ap-
plications which send/receive messages using CMM are Industry Libraries such as the Production Order
Handling library (ILH-POH), and the Process Management library (ILH-PRO).
• Logging Management Library (FRM-LOG) provides useful instruments for logging information from the
rules running in the Production Modeler on to a database.
• Compliance Management Library (FRM-CPM) can be used in any kind of industry which may need to
enforce compliance to a given set of Regulatory Code Rules. Two are the features that the library pro-
vides:
o Electronic Signature (ES) intended as the authentication of a specific user. If associated to an
action, for the action to be terminated the user must perform an authentication by inserting
the proper username and password.
o Audit Trail (AT), intended as a log operation.
• Configuration Library (FRM-CNF) which provides a set of functionalities to configure the libraries in-
cluded in the collection such as configuring web keys, manager attributes, enabling and disabling user
exits and so on.

4.2 Factory in a Box Secondary

The Factory in a Box Secondary is a collection of several Hybrid-Industry Libraries (ILH) and Basic-
Framework Libraries (FRM).
Typically, secondary production consists in sub-phases such as Filling, Packaging, and Palletizing.
These libraries have been brought together and partially pre-configured in order to cover the most com-
mon functional requirements of the secondary production phase.
 ERP integration for order and master data
 Master Data management, BOM, Routing
 Product and production validation
 Production Order for finish good / packaging
 Plant orders for CU,SKU,SSCC
 Production and consumption declaration
 Label management for CU,SKU,SSCC
 Pallet management
 Container Management
 Delivery to warehouse or shipping
 Automation Integration (DCC-DCO)

Here is a complete list of the included libraries:

• Production Order Handling Library (ILH-POH) handles production orders at MES level, specifically tai-
lored for Orders in the Secondary Process. The library focuses on the engineering side of orders and
entries management, and it addresses especially a supervisor user, who engineers the production and
monitors the runtime.

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 14

• Process Management Library (ILH-PRO) handles each sub-step of production, from the order initializa-
tion to the completion. The library focuses on the runtime phase of a production step, managing activ-
ities such as order dispatch, material declaration and consumption, download of parameters to Control
Level, and so on.
• Pallet Management Library (ILH-PAL) permits creating pallets and movable containers, that are typical-
ly reusable pallets (that can be empty or with one or more lots inside) and are used to move amounts
of material at the end of Secondary Production. Pallets are also called Logistic Unit – LU – stage.
• Labeling Management Library (ILH-LBL) provides the basic functionalities to create label data and to
configure label templates, tailored for Secondary Phase and in particular labeling of CU (Consumer
Units, e.g. a single bottle), SKU (Stock Keeping Units, e.g. a carton of 6 bottles), and LU (Logistic Units,
e.g. a pallet).
• Line Management Library (ILH-LMG) allows the creation and maintenance of virtual lines.
• Recipe Management Library (ILH-RCM) handles recipe management for production plants.
• Lot Information Library (FRM-LIN) allows the user to view Material Lots and their Genealogy Links.
• Material Management Library (FRM-MTL) handles the materials in a production system.
• Corrective Action Management Library (CIL-CAM) allows managing Corrective Actions (CA) which are
actions that can be performed during run time plant functioning to recover, for instance, to critical
situations.
• Electronic Work Instruction Library (CIL-EWI) allows the operator to manage Electronic Work Instruc-
tions which are forms containing a list of instructions that must be read to understand an operation
that has to be done and has to be filled by the operator to check important production variables.
• Tank Farm Management Library (ILH-TFM) manages the movements of materials between tanks in a
plant and allows external applications (e.g. other libraries) to search for material within the tanks or
for tanks where they can place material.
• Communication Management Library (ILH-CMM) allows messages to be exchanged between external
systems and Manufacturing Execution System (MES) applications. A typical example of an external
system which needs to send/receive messages to/from MES is the Control Layer. Examples of MES ap-
plications which send/receive messages using CMM are Industry Libraries such as the Production Order
Handling library (ILH-POH), and the Process Management library (ILH-PRO).
• Logging Management Library (FRM-LOG) provides useful instruments for logging information from the
rules running in the Production Modeler on to a database.
• Compliance Management Library (FRM-CPM) can be used in any kind of industry which may need to
enforce compliance to a given set of Regulatory Code Rules. Two are the features that the library pro-
vides:
o Electronic Signature (ES) intended as the authentication of a specific user. If associated to an
action, for the action to be terminated the user must perform an authentication by inserting
the proper username and password.
o Audit Trail (AT), intended as a log operation.
• Configuration Library (FRM-CNF) which provides a set of functionalities to configure the libraries in-
cluded in the collection such as configuring web keys, manager attributes, enabling and disabling user
exits and so on.
• Reporting Framework - Secondary which provides the collection data model for reporting.

4.3 Integrated Quality

The Integrated Quality is a collection of several Hybrid-Industry Libraries (ILH) and Basic-Framework Librar-
ies (FRM).
This library is built to support the operators to perform the in-line and at-line quality operations. The key
benefits from implementing such a solution are:
Improvement in product consistency & Food Safety
• Reduction of rework and production scrap
• Real time product and process quality control

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 15

• Right first time, TQM, Six sigma programs enabler

• SOP standardization across different production facilities
The main functionalities implemented are the following:
• Hazard Analysis and Critical Control Points (HACCP) Management
• Statistical Process Control (SPC)
• Forms-based Electronic Work Instructions (EWI)
• Defect Tracking
• Net Contents Control
• Corrective Action Management (via alerts, email, SMS, or custom rules)

4.4 Logistics
The Logistics is a collection of several Hybrid-Industry Libraries (ILH) and Basic-Framework Libraries (FRM).
These have been brought together and partially pre-configured in order to cover the most common func-
tional requirements of the Load In and Load Out phases and the Warehouse Management.
Here is a complete list of the included libraries:
• Warehouse Management Library (ILH-WHM), which handles the storage of materials within a physical
area named Warehouse.
• Load-In/Load-Out Library (ILH-LOA), which manages the Load-In / Load-Out operation, for example the
arrival or departure of a carrier, lot and pallet registration linked to the purchase order, and so on.
• Communication Management Library (ILH-CMM) allows messages to be exchanged between external
systems and Manufacturing Execution System (MES) applications. A typical example of an external
system which needs to send/receive messages to/from MES is the Control Layer.
• Logging Management Library (FRM-LOG) provides useful instruments for logging information from the
rules running in the Production Modeler on to a database.

4.5 Data Concentrator/Data Coordinator Collections (DCC-DCO)

Process libraries provide three collections in the Data Concentrator/Data Coordinator group:
• Data Concentrator (ILH-DCC)
• Data Coordinator for Primary (ILH-DCCDCO_PRI)
• Data Coordinator for Secondary (ILH-DCCDCO_SEC)
They provide a link between the Manufacturing Execution System (MES) and the Controls System (the
Control System identifies here all the Low Level Automation (LLA) controllers present in a plant).
They communicate with MES using standardized XML messages and with LLA PLCs using a Data Block-
oriented communication.
Other communication solutions may be used by adopting customized logics. The communication is used to
download data to the line PLCs as well as to control and monitor the execution of the related operations.
Appropriate configuration and customization allow the integration of Control Systems from different ven-
dors and thus suite the customer plant specific logic.
A standardized solution of communication between MES and the LLA layer is a need that must be fulfilled
in order to make the development easier, modular, transparent, and time saving.
The two dedicated verticalizations, for primary and secondary areas, are composed by two modules:
• The Data Concentrator (DCC)
• The Data Coordinator (DCO)

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 16

4.5.1 The Data Concentrator (DCC)

The aim of the Data Concentrator (DCC) is to build a standardized and reliable message-based communica-
tion interface between the MES and the Automation Layer. The communication technology used herein is
compliant with the SIMATIC IT ILH-CMM Process Library.
DCC buffers events (from automation to MES) and orders (from MES to automation), assuring that no data
is lost.

4.5.2 The Data Coordinator (DCO)

The Data Coordinator (DCO) is a “Process-Runtime-Area” located in the Automation Layer, which is capable
of handling processes operating at the Unit level and it is fully compliant with the S88 standards.
The goal is to provide a general solution usable in different scenarios. For example:
• Connection to Siemens and non Siemens PLC hardware with old programming
• Replacement of ProCX without touching the Automation Layer
• Complete newly deployed automation systems based on S88
The solution is a generic shell that hides the Plant-specific process modeled on the Unit Level. The process
to be managed is plant specific, but the shell is always the same.
It wraps the basic functions and goes close together with the Data Concentrator and the MES Library func-
tions for the Production Orders handling.
DCO primary delivers predefined functionality for primary processes in combination with the SIMATIC IT
primary library collection.
DCO secondary delivers predefined functionality for primary processes in combination with the SIMATIC IT
secondary library collection.
In case MES is temporary disconnected from the plant, DCC/DCO allows to operate the production process
in “degradated mode”. A set of WinCC pages are available for directly operating the DCC/DCO from the
Scada screen.

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 17

5 Major features in version 3.3

5.1 What’s New in Industry Libraries Hybrid for Process v 3.3

• Usability

• New functionalities

• Support for French and Spanish languages

• Configuration import/export support (limited to system configuration)

• Automatic Installation and Configuration Enhancements

In detail:

5.2 SIMATIC IT ILH Primary

• Recipe Management consistency check: Adding the possibility to Health Check a recipe (PPR) direct-
ly from the Recipe Management screen

• Orders page selection using equipment as filter: Add filters to selects Orders that contains opera-
tions running/scheduled on a set of equipments

• Order pages refresh only on events: A order page is refreshed only at the status change event of its
operations

• HLWF UI Customization: Allows the HLWF UI customization allowing to modify configuration files

• Management of CMM unprocessed messages: Add a page to list the CMM unprocessed messages to
allow their selection and eventually re-processing them manually

• Process global context mechanism support: Set Operator parameters at the beginning of the work-
ing time and show all pages filtered using these parameters

5.3 SIMATIC IT ILH Secondary

• Synoptic Line Screen to show data from Secondary collection and other SIT modules. It is available a
screen (“Synoptic”) to show information from Quality, OEE, Production, Maintenance, Energy mod-
ules.

• Orders page selection using equipment as filter: Add filters to selects Orders that contains opera-
tions running/scheduled on a set of equipments

• Order pages refresh only on events: A order page is refreshed only at the status change event of its
operations

• Manage the commands Abort, Hold; Complete at order level: The capability has been extended
also to the Order Level (not only at operations level)

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 18

• Set a default routing for a Virtual Line: Allow to set a default routing among the possible alterna-
tives and use it at the order creation

• At the restart of an order or an operation change the equipment where to execute it. It allows
to modify and select a new equipment at the restart of an order or an operation

• Align the operations list when DCC-DCO create new operations for a running order. Add the
capability to receive messages from DCC-DCO

• Configuration and execution of a recipe containing manual operations ( EWI) mixed with au-
tomatic production Operations (DCC-DCO): Add the capability to configure and execute a recipe
where automated process operations need to be controlled and synchronized with manual opera-
tions. It creates a secondary order with automatic entries as a workflow and manage the download to
DCC-DCO

• Run command at order level integrated with DCC-DCO: Add the capability to send Run command at
order level

• Configuration of Virtual Lines taking into consideration the physical connections: Add the capa-
bility to support the virtual line configuration selecting an equipment and automatically provide the
routing depending on the physical lay-out.

• Alignment of workflow orders executed at DCC-DCO level in degraded mode: Add the capability
to receive message from DCC-DCO and update orders as soon as the communication is re-established.
After the re-alignment, the pending operation of the order must be handled manually

• Management of CMM unprocessed messages: Add a page to list the CMM unprocessed messages to
allow their selection and eventually re-processing them manually

• HLWF UI Customization: Allows the HLWF UI customization allowing to modify configuration files
relevant for the UI lay-out

• Manage set of parameters relevant for a set of equipment and depending from the recipe. Dur-
ing the recipe configuration, add the capability to define and manage properties relevant for the
set of selected equipment

• Association of virtual lines to Recipe: Per each recipe, the user can select one o more virtual lines to
associate to it , eventually according to the material specification. The association is propagated to
segments of the recipe linking the proper equipment.

• Process global context mechanism support: Set Operator parameters at the beginning of the work-
ing time and show all pages filtered using these parameters

5.4 SIMATIC IT ILH Integrated Quality

• Usage of not contextualized SPC-Control Plan in Quality Module. Add the possibility to link a not
contextualized SPC-Control Plan to a Quality Task definition during the engineering phase and to ac-
tualize it at run-time. Configuration of not contextualized SPC –CP has been added to SPC module

• Form Web Editor from SIT Portal. Add the capability to define forms from a web page to improve the
form configuration (avoid to use dedicated tool)

• SPC: pre-configuration of the Pareto Chart. Add the capability to pre-configure Pareto Chart (pre-
configured list of characteristics) to reduce mis-configuration problems

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 19

• SPC: Show Control Limits values in the chart details’ panel. Show the control limits values per
each points in the chart details panel at each subgroup selection

• Simplify the IQ engineering editing. Effort to change/edit the quality tasks configuration has been
reduced in terms clicks and steps

• Search and Display executed Quality tasks. Add the capability to search for quality tasks based on
test results, time and context (Order, shift, products, etc) . For failed Quality task, the operator will be
able to drill down into the failed parameters

• Centralized Limit s Configuration. Add the possibility to have one single repository to define all
measures’ limits contextualized by products and/or equipment

• Allow “amend” operation on already executed manual data acquisition. Provide to authorized
personnel the capability to change/modify data wrongly entered.

• Set context data at Correcttive Action rule start. When a task violation occurs, provide context
ualized data to the corrective action rule

• Show SPC results in WFM. Add the capability to show SPC results (SPC task values) from WFM pages

• SPC save limits in run-time to simplify data consistency check. Add the capability to save the con-
trol limits together with the subgroup values.

• Allow to skip the Corrective Action execution. Add the capability to add and execute customer
specific logic to decide if a Corrective Action has to be executed or not (user Exit and relevant context
data)

• Associate to a workflow more than one event inside one IQ Plan. Add the capability to replicate
the same workflow in a PLAN for each event that can trigger it.

• Associate to a workflow more than one equipment on which the test has to be executed. Add the
capability to link a set of equipment (site, area, cell, unit) to a workflow in configuration phase and
actualize the triggering unit at run time.

• Show EWI results in WFM. Add the capability to show EWI results (EWI task values) from WFM pages

• Show ALT limits violations in WFM. Add the capability to show ALT results (ALT limits violations)
from WFM approval pages

• Process global context mechanism support. Set Operator parameters at the beginning of the work-
ing time and show all pages filtered using these parameters

5.5 SIMATIC IT ILH Logistics *

(*) ILH Options include : Loadin-LoadOut; Warehouse;

• Hand Held move procedure. From an Hand held device, extend the capability to move material trac-
ing information on the system database

• Historical information about materials movements duration. Add capability to track the start time
and end time of movements

• Process global context mechanism support. Set Operator parameters at the beginning of the work-
ing time and show all pages filtered using these parameters

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Functional Overview | SIMATIC IT Industry Libraries Hybrid for Process | June 2013 20

5.6 SIMATIC IT ILH DCC-DCO for Primary and Secondary *

(*) DCC-DCO is available for Primary and Secondary process. In this version, DCC-DCO for Primary does not
provide any modifications.

• Manage the commands at order level. Add the capability to set commands not only at operations
level but also at order level

• Add new operation in a order already in execution. Order workflow is up and running but it needs
to be modified on “the fly”. Allow the creation of a new operation associated to an already running
order at MES and then download to the DCC-DCO.

• At the restart of an order or an operation, change the equipment where to execute it. It allows
to modify and select a new equipment at the restart of an order or an operation on the MES and then
downloaded to DCC-DCO

• Extend the management of parameters associated to material and operations. All the parameters
associated to an entry/operation must be managed at Operation level, Material Level, Equipment level.

• Add string type parameters. The type “ string” has been added to the parameter types list

• Extend the equipment dictionary to map MES equipment parameters. Add the capability to trans-
late parameters into/from the low-level and MES format.

• Workflow orders execution interfacing DCC-DCO. Add the capability to receive orders and com-
mands from MES also when the order scheduling is managed by workflow.
DCC-DCO is slave of the MES workflow

• L-COM Integration. Add the capability to read/write from another PLC (Restricted to Siemens Family)
on the same LLA network

• HMI functionality in Degraded Mode (Copy Operation). Extend the DCC-DCO HMI to add the capa-
bility to copy locally an operation already available and to let the operator adjust the related order in
degraded mode

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