Extensions of relevant general models

Admittedly, the industry currently supports many methodologies that define formal procedures specifying the process of gathering, analyzing applications’ requirements and incorporating them into a program design. But still the complexity is very high. One characteristic of UML—also the one enables the widespread industry support that the language enjoys-is that it is methodology-independent.

The design of the following object models are based on basic knowledge of industrial system manual books. As we know, several different projects may be required in case of developing and updating the original system later. The building of models must consider multiple levels of applications and face varying requirements from consumers to maximize the benefit. While in this thesis, in fact also in most of the researches, modeller focuses on the initial development project and not on the supporting projects [8]. In other words, the primary concern of the thesis is to get an industrial system operated and operated the very first time.

ISA-95 standard book also gives reference for expanding the classes. For example, in 7.3.2.1 in ANSI/ISA-95.00.01, it defines personnel class as follow:

“A personnel class is a means to describe a grouping of persons with similar characteristics for purposes of scheduling and planning. Any person may be a member of zero or more personnel classes [36].”

Examples of the objects in a class in given:

Examples of personnel classes are “cook machine mechanics,” “slicing machine operators,” “cat-cracker operator,” and “zipper line inspectors”.

As one of the possible scenarios in industrial systems, the extension of personnel class is visualized by the generalization between “operator” class, “engineer” class and

“personnel class” (Figure 3.8). This structure shows the taxonomic relationship between a more general element (the parent—personnel class) and a more specific element (the child class—operator, engineer) that is fully consistent with the first element and that adds additional information.

Also, the associations between 2 child classes and the qualification tests are built.

Figure 3.8 an example of extension of Personnel Class for Industrial System Another issue worth being mentioned is that in most of the cases, attributes have large flexibility. As indicated in Table 1, the title or even the data type can contain different variation.

Table 3 an example of person property attributes

UML notation used in the models is attached as Appendix 4. The general models and description on the models built for the 2 lines are as follow:

3.4.1 Personnel Model

The personnel model contains the information about specific personnel, classes of personnel, and qualifications of personnel.

Figure 3.9 Personnel model

And with FASTory-Line’s high level of automation, the requirements for personnel are comparatively low. Some of the attributes in this part can be left blank.

3.4.2 Equipment Model

The Equipment model contains the information about specific equipment, the classes of equipment, equipment capability tests, and maintenance information associated with equipment.

Figure 3.10 Equipment Model

3.4.3 Material Model

The material model defines the actual materials, material definitions, and information about classes of material definitions. Material information includes the inventory of raw, finished, and intermediate materials. The current material information is contained

Figure 3.11 Material model

The expression of data should be in accordance with consumers’ requirements. E.g., the colour here can be called red, green and blue directly. But for a higher resolution, the entity can also be called by its hue and saturation.

The material model built for FESTO Line defines the actual materials, material definitions, and information about classes of material definitions. Material information includes the inventory of raw, finished, and intermediate materials. The current material information is contained in the material lot and material sublot information. Material classes are defined to organize materials. In this material model, the generalization relations between “material class” and classes as “spring”, “piston” are expressed by arrow lines. And so is the generalization of “material lot class” and classes as

“SilverCylinder”, “BlackCylinder” and so on.

3.4.4 Production Capability Model

The production capability information is the collection of information about all resources for production for selected times. This is made up of information about equipment, material, personnel, and process segments. It describes the names, terms, statuses, and quantities of which the manufacturing control system has knowledge. The production capability information contains the ‘vocabulary’ for capacity scheduling and maintenance information.

Figure 3.12 Production capability model

In this model, where persons are members of multiple personnel classes then the personnel capability information defined by personnel class should be used carefully because of possible double counts, and personnel resources should be managed at the instance level.

Obviously, the personnel capability attributes defined here, double counts with personnel classes and there are no significant differences between them。So this object should be deleted or ignored.

Moreover, take the personnel capability attributes as an example, when attributes as

“Capability Type”, “Location” and “Reason” are the same as that in Production capability attributes, they should also not be counted in. ISA-95.00.02-2001 Annex A shows simplified examples of multiple models in practical use.

3.4.5 Process Segment Model

A process segment is a logical grouping of personnel resources, equipment resources, and material required to carry out a production step.

Figure 3.13 Process Segment Model

3.4.6 Process Segment Capability Model

A process segment capability is defined as a logical grouping of personnel resources, equipment resources, and material that is committed, available, or unavailable for a defined process segment for a specific time. It is related to one or more than one products segment that can occur during production.

Figure 3.14 Process segment capability for FASTory Line

For presenting the change of the process segments between “AS-IS” and “TO-BE”, 2 separate process segment models are built for the production lines. The 2 process segment models contains also majority of the information for both of the systems and the transformation.

3.4.7 Production Schedule Model

Production information is defined in two model correspond to requests for production and responses to the requests.

Figure 3.15 Production schedule model

There are multiple segments defined in the example. There is one master segment of production that applies to the entire production request. The master segment is made up of multiple nested segments for individually specified and reported segments of production [37].

The rest parts attributes in the model, including personnel requirement and its property, equipment requirement and its property, material produced requirement and its property, material consumed requirement and its property, consumable expected and its property are not necessary.

3.4.8 Production Performance Model

The performance of the requested manufacturing requests is the production performance. Production performance is a collection of production responses.

Figure 3.16 Production Response Model

There are multiple segments defined in the example. There is one master segment of production that applies to the entire production response. The master segment is made up of multiple nested segments for individually reported segments of production [38].

3.4.9 Product Definition Information Model

The product definition information is information shared between production rules, bill of material, and bill of resources.

Figure 3.17 Product definition model

FASTory Line is still in development state, some actual data can only be got after it’s fully tested. As a result, the attributes of personnel actual attributes and personnel actual property are to be announced.