MES oriented system create d in Saint-Gobain Sekurit Poland. How Python help build MES system

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SEKURIT
BRAND
LOGO
CASE-STUDY ABOUT
BUILD MES
INTEGRATION SYSTEM
IN AUTOMOTIVE.
Przemysław Wojtunik

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I’m
Przemysław Wojtunik
przemyslaw.wojtunik(at)saint-gobain.com
I’m
IT MANAGER
DEVELOPER TEAM LEADER
DEVELOPER
I work at
SAINT-GOBAIN Sekurit
About me

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Case-study how we are use Python to
help make car glass
Today

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SAINT-GOBAIN

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MES system
Manufacturing executionsystems (MES)
are computerized systems used
in manufacturing
WHY WE NEED MES ?
• Reduced waste, re-work andscrap,
includingquicker setup times
• More accurate capture of cost-
information
• Increaseduptime
• Paperless Workflow Activities
Planning Level
ERP
Execution Level
MES
Control Level
SCADA/PLC

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MES
Why Python ?

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What is Tesseract ?
Tesseract platform for build applications
for business and manufacturing
Elementsof platform:
Data storage – BigData solution (MongoDB) and PostgreSQL
Programming – Python 3.6
Web Framework – Django
Django Channels - Async for UI
Streaming data - Apache Kafka
Lots of service run in Docker
 World implementation in Saint-Gobain Sekurit plant
 Terabyte's of data per each instance, billions records
 Full horizontal scale solution
 Polish Team responsible for project, development and maintenance

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TESSERACT
Production modules:
• Downtime declaration – declaration dow nload
and type of production
• Scrap – declaration manual/automation scraps
Connectivity:
• OPC-UA – Integration w ith OPC-UA Server
• Raspberry PI – dedicated microcomputer for
connecting signals from PLC
• MQTT – Integration w ith IoT Gatew ay
Integration:
• Data Streaming - integration over Apache
Kafka to Data Lake (CDH)
• SAP ME – integration w ith SAP ME
Quality modules:
• Optics Glass
• Printing quality
• Geometry Glass
• Heating Glass Scanners
Visualization processdata:
• Sensors - visualization process parameters
• Visualization - process, w orkcenter on layout
Other modules:
• Energy modules – energy modules
• Process Control – process release production
• E-Checking – AM, PM, Process Audit, 5S
Audit
Workshop visualization:
• AndonTV – present result for shopflow
• Dashboard TV – present Tesseract dashboard
Event&Action:
• Event&Action – events that can generate alerts
Email, Notification, SMS message, API external
Tesseract

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Tesseract
Connectivity
MES TESSERACT PYTHON
Relationship with
Level 0, 1, 2 systems
PLC – Programmable
logic controller
Raspberry Pi
• Signal from PLC
• Signal form laser sensors
• Sensors data
• Display to present live data
OPC-UA - implementas clientand server
• Process data from sensors
• Counters
IoT Gateway - implementedMQTTprotocol
• Python codes run on
Raspberry PI
• python-opcua
• paho-mqtt

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Tesseract
Connectivity
010010111101111
Transform signal declaration
volume
from multiprocessing import Process
from multiprocessing import Queue
from multiprocessing.sharedctypes import Value
from tesloserver.core.DB.db import DBImport, RESTApi
from tesloserver.core.Settings import TSettings
from tesloserver.core.utils.GPIO import GPIOReadData,
GPIOReadDataRev
from tesloserver.core.opcua.server import run_server
from tesloserver.core.modbus.client import modbus_worker
from tesloserver import __version__ as VERSION
TESSERACT

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Tesseract
Connectivity
Counters, values
Tesseract
Services
IoT Gateway
PLC
MQTT Broker
OPC-UA Server
from multiprocessing import Process
from multiprocessing import Queue
from multiprocessing.sharedctypes import Value
from tesseract_service_mqtt.core.Settings import TSettings
from tesseract_service_mqtt.core.workers import mqtt_service
from tesseract_service_opc_ua.core.utils.tesseract_opc_ua
import OPCServer
TESSERACT
Transfer data, Read
information for subscribes

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MES TESSERACT PYTHON
• Production and
visualization in
progressin real time
• Real time productivity
of machines
• Downtime and reasons
for downtimes
• Live data from production line
• Declaration losses, comment
• Dashboard technology for users
• Widget representing live data and results
django-channels
Tesseract
Production modules

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MES TESSERACT PYTHON
• Defectsand scraps
• Scraps reporting application
• Reporting pages over product, campaign, model
• Different widget for dashboard
• Presenting result as map of defect
django-channels
Tesseract
Production modules

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MES TESSERACT PYTHON
• Defectsand scraps
django-channels
Tesseract
Production modules

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Tesseract
Production modules
from tesseract_core.widget.bokeh import TesseractBokehWidget
from tesseract_core.widget import TesseractBaseWidget,
TesseractDashboard
class BaseLineWidget(TesseractBokehWidget):
permission_object = models.CorePerm.widget_perm_id()
permission_group = models.CorePerm.widget_perm_id()
module_name = __module_name__
edit_template =
"tesseract_core/widget/edit_widget_tab_bokeh.html"
edit_horizonal = [6, 8, 10, 12]
edit_vertical = [100, 150, 200, 250, 300, 350, 400]

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MES TESSERACT PYTHON
• Collecting information
from quality systems
• Most of quality system is closed
• Lots of transformation data and binary elements
• Lots of strange custom format data
• Apache Kafka as stream data
Tesseract
Quality modules

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Tesseract
Quality modules
Transfer clean data
# Configuration regarding topics
Topics:
- name: 201.tesseract-service-sadap.0
backend: mongodb # restapi, mongodb, kafka
description: Sadap Data
hosts:
- test1:27000
user: xx
password: xxx
dbname: SADAP
collection: Sadap
class_obj: !!python/object:tesseract_service_kafka.topics.TopicEngineSadap {}
- name: 201.tesseract-service-datatemp.0
backend: mongodb # restapi, mongodb, kafka
descript: DataTempScanner
hosts:
- test1: 27000
user: xx
password: xxx
dbname: DataTempScanner
collection: DataTemp
class_obj: !!python/object:tesseract_service_kafka.topics.TopicEngineDataTemp
{}

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MES TESSERACT PYTHON
• Collecting information
from quality systems
• Reports and data analyses
Tesseract
Quality modules

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MES TESSERACT PYTHON
• Collecting information
from quality systems
• Data analyses pages
• Presenting result as map of defect
Tesseract
Quality modules

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MES TESSERACT PYTHON
• Production process
data
• Statistical process
data
• Sensors module present data from process parameter
• Different widgets presenting sensors data
• Visualization process, workcenter
• Process statisticscontrol
Tesseract
Visualization and process data

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MES TESSERACT PYTHON
• Production process
data
• Statistical process
data
• Reports pages
Tesseract
Visualization and process data

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MES TESSERACT PYTHON
• Notification of stops
occurring during
production
• Tesseract Event & Action save all events.
• All users that subscribed the same events can share comments on single
event.
• Notification activity time (24h/7, 6-22 mon-fri, 24h mon-fri).
• Users can choice type of action (SMS, E-mail, Notification in system,
others systems)
Tesseract
Event &Action

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MES TESSERACT PYTHON
• Document
management
• Maintenance
management
• Energy and Powercurrent consumption
• Analysis of Energy consumption
• Full customizedPlant Board/Machine Board solutionandPCS
Board
• InternalWorkflowBPM systems
• Application with possibility to build routine AM,PM,Process
Viewinspection
• ControlProcess – fullsystem with build release card and
process release on production area
Tesseract
Other modules

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MES TESSERACT PYTHON
• ERP integration
Integrationwith SAP system overSAP ME
• Master Data, Resource, Material
• Reporting production declaration Downtime
• Scrap and defect declaration
ControlTower
Tesseract
Integration

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Tesseract

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THANK YOU