KAIST

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1st KAIST-TU/e Workshop on Business Process
Management TU/e Eindhoven, Netherlands
A BPMS Framework for RFID-based Manufacturing
Operation Management (PROMISE PROduct
life-cycle Management and Information tracking
using Smart Embedded Systems)
August 31, 2007 Prof. Byoung K. Choi VMS Lab IE
Department, KAIST
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A BPMS Framework for RFID-based Manufacturing
Operation Management

• Target Manufacturing System (Straw Mfg)
• Production Data Acquisition System
• Database for Production History and WIP
• Workflow-based Manufacturing Operation Management
• Development of Infrastructure Technology
• Conclusion and Discussion

Contents
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1. Target Manufacturing System

• 1. Company Overview (SEOIL Industrial Co. Ltd)
• - 1979 Founded in Korea Production of Straw and
  its manufacturing
• - Established factories in Korea, China, USA, and
  Indonesia
• - 30 million dollars of revenue (Korea office)
  and 150 employees
• - Annual Output 4.5 billion pieces (45? ?)

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1. Target Manufacturing System
2. Product Lines
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1. Target Manufacturing System
3. Factory Layout and Production Flow (PE-Straw)
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Mixing
Empty Box Return
Raw MaterialStorage Area
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1
3
Extrusion
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10
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Forming Assembly
Aging
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Office Area
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FinishedProductStorageArea
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Shipping
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1. Target Manufacturing System
4. BPMS Requirements Analysis and Design

Data Acquisition Analysis
Key Business Process Analysis (Claim Handling
Order Handling)

Database Design (Production History DB, WIP
Order Status DB)
Data Acquisition System Design (RFID, Webpad,
Scanning)

Data Transaction Workflow Design
Claim Handling Workflow Design
Order Handling Workflow Design
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2. Production Data Acquisition System
1. Design of DAS (Data Acquisition System)
Configuration
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A
Raw MaterialStorage Area
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1
3
M
B
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Real-time Monitoring
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Office Area
C
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FinishedProductStorageArea
RFID Reader
Webpad
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DB Server
Scanner
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2. Production Data Acquisition System
2. Determination of Data Items to be Collected
Run-time monitoring Machine-id, Temp, Pressure,
Time ? Monitoring computer
M
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Scanner
Bare-straw inspect M-id, Worker-id, Order-id,
Inspect, Time? Inspect Report-1?
Boxing Lot-id, Tag-id, M/W/O-id, Start-time,
End-time, Quantity ? Webpad
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Transport to aging Tag-id, Time ? RFID reader
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Transport to forming Tag-id, Time ? RFID
reader
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Scanner
Bare-straw loading M/W-id, Lot-id, Tag-id,
Start-time, End-time? Loading Report?
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Scanner
PE-straw inspect M-id, W-id, Order-id, Inspect,
Time? Inspect Report-2?
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Packaging Lot-id, TAG-id, M/W/O-id, Start-time,
End-time, Quantity ? Webpad
B
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Transport to storage TAG-id, Time,
PalletTag-id ? RFID reader
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PE-straw storage Pallet-id, Order-id,
Rack-number, Time ? Webpad
C
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Shipping inspection PalletTag-id, Order-id,
Freighter-id, Time, Quantity ? Webpad
D
Shipping PalletTag-id, TAG-id, Time ? RFID
reader
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Tag-id Handling box (bare straw)
TAG-id Shipping box (finished
PE straw)
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3. Database for Production History and WIP
1. Design of Production History Repository (DB)
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3. Database for Production History and WIP
2. Design of WIP and Order Status Repository (DB)
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4. Workflow-based Manufacturing Operation
Management
1. Framework of Workflow-based Operation
Management
Production line

RFID Middleware
Web pad Application
Scanned RecordApplication



Data transaction workflow
BPMS (Enactment Service)
ProductionHistory Repository
WIP Order Status Repository

Claim handling workflow
Order handling workflow
User Application
User Application
Operations, QC, Sales.
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4. Workflow-based Manufacturing Operation
Management
2. RFID Data Transaction Workflow
Reader-to-DB Mapping Table
Workflow Example (for Reader 3)

• Receive an ALE from RFID middleware ReaderR3,
  TAG-id99999, Time070829/1430
• Find LOT-id for the TAG-id from the Forming DB
  (LOT-id 12345
• Insert a record into the Move-Event DB LOT-id
  12345, TAG-id 99999, Forming-Area Out-Time
  070829/1430
• Delete the record with TAG-id 99999 from the
  Forming-Area WIP DB
• Insert the deleted record into the Warehouse
  PE-Straw DB with In-time 070829/1430
• Find the record with TAG-id 99999 from the
  PE-Straw Order Status DB, andupdate (increase)
  its Warehouse Inventory Qty (by Quantity)

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4. Workflow-based Manufacturing Operation
Management
3. Scanned Record Transaction Workflow
Manually Recorded Shop-floor Data
Straw-inspection data (bare-straw and PE-straw)
and machine-loading data are recorded on
form-sheets by operators during production. In
order to trace the production history of the
product, the sheets (Inspect-Report-1,
Inspect-Report-2, and Loading-Report) are to be
stored in DB together with search keys.
Workflow Example (Inspect-Report-2)

• Bring all inspection reports to office at the end
  of a shift.(Shop manager)
• Scan each report and save it using Adobe
  PhotoShop. - File-name Shift-MachineID-OrderID
  (Production office)
• Store each scanned file into the PE-Straw Inspect
  DB- Search-key Shift, MachineID, OrderID (IT
  office)

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4. Workflow-based Manufacturing Operation
Management
4. Claim Handling Workflow (To-be Model)
There are 3050 claims per year. The customer
asks to perform FMEA for the defect. 1) Case-1
LOT known, 2) Case-2 Order known, 3) Case-3
No information
1) Get Machine-id, Start-time, End-time from the
Forming DB 2) Determine Shift from Start-time and
End-time 3) Locate the inspection report from the
PE-Straw Inspect DB using Shift, Machine-id
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5. Development of Infrastructure Technology
1. Development of RFID Middleware (KAU)
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5. Development of Infrastructure Technology
2. Development of BPM System ALE Interface
(KAIST)
BPM System (Harmony)
Workflow API(WAPI, WBDO)
Workflow Engine (Enactment Service)
Workflow Data Access Component
Internal Event Monitor
Embedded Simulator
Server Agent
Plug-in Simulator
Application Adaptor
External Event Handler
ALE Interface
RFID Middleware
EPC Data (Reader Protocol)
Reader
Reader
Reader
Reader
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5. Development of Infrastructure Technology
3. Development of Machine Monitoring System
(KITECH)
Real-time monitoring of pressure and temperature
data of the extruding machines using a USN/Zigbee
module in order anticipate the filter-exchanges
time
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6. Conclusion and Discussion
1. Project Scope
It is a part of Korean IMS PROMISE Project titled
Management of Product Lifecycle with
RFID/USN. Participating institutions are KAU,
KAIST, KITECH and SEOIL (participating company)
2. Progress
It is the second year of a two year project
(2006.3.12008.2.29) and now working on
developinga prototype system (The first year was
devoted to developing infrastructure technology).
During the second year, KAIST has developed1)
Framework for Production Data Acquisition (in
collaboration with KAU) 2) Specification of
Production History DB and WIP DB 3) Framework for
Workflow-based Manufacturing Operation Management
3. Implementation Plan
Only a subset of the proposed framework may be
implemented due to budget limitation
(about20,000 USD/year) and practical constraints
(The company wants to start small and simple)
4. Lessons Learned
-It was a fun (and relatively easy) to develop a
framework, but
-Issues of justifying the benefit of introducing
RFID in manufacturing management in a SME
-Issues of managing the increased complexity due
to RFID introduction
Thank you for your attention! QA