The contents of this page are extensive since the migration process is detailed and requires deep knowledge of the products. Please read through each section, understanding the implications prior to performing a migration. Please contact Sepasoft support at 800 207 5506 with any questions or concerns regarding this process. PERFORM THIS MIGRATION ON A DEVELOPMENT SYSTEM FIRST, as described below.
SPC and Recipe Data Migration
In 2011 Sepasoft developed the OEE/Downtime Tracking module for the Ignition platform, extending the capabilities of this predominantly SCADA solution into the MES domain. Over the years since its introduction, our certified systems integrators, clients and our own team at Sepasoft learnt a great deal about how a company’s manufacturing base wants to use OEE to drive continuous improvement initiatives. With that in mind, the OEE module has evolved continuously to handle ever more complex production lines, analytical requirements and large scale enterprise architectures.
In 2014, our Track & Trace module was released following on the heels of the SPC, Instrument Interface and Recipe Management modules. Track & Trace heralded a new and significant chapter for us with the decision to base it on the ISA-95 standard and object model. This new framework provides a powerful and flexible platform that can be used to create custom MES solutions to manage every aspect of manufacturing operations and the required equipment, personnel and material resources.
With the growing popularity of the OEE module, the new requirements being sought and ever increasing OEE + Track & Trace implementations, the decision was made to completely revamp the OEE module to use the same ISA-95 object model as Track & Trace, providing a seamless integration between lot tracking, production control, scheduling, resource management and OEE analytics. Because of this, it was no longer possible to maintain backwards compatibility with OEE 1.0 as the differences were too great. This document intends to lay out the difference between OEE 1.0 and OEE 2.0 and to provide a path for migrating from OEE 1.0 to 2.0.
You will see references to MES 1.0 and MES 2.0 throughout the documentation. Changes were made to the underlying MES platform on which all modules run as part of the OEE 2.0 module development. Minor changes were made to existing Track & Trace, SPC and Recipe Management modules to account for the MES 2.0 platform changes and those modules will have a 2.x.x version. Instrument Interface, Web Services, Barcode scanner and the production simulator are not affected by the MES platform changes and 1.x.x versions can be used.
Licensing and Migration
OEE 2.0 provides greatly enhanced production modelling and analytical capabilities that make a strong case when considering replacing an existing OEE 1.0 implementation. There is no additional license cost for using OEE 2.0 as long as you have a license for OEE 1.0 and upgrade protection is active on your license. We provide migration tools to help with porting over an existing OEE 1.0 implementation and bringing over historical production data. There are however significant changes that will need to be made to replace any screens that use legacy OEE 1.0 components and scripting functions which are outlined in the sections below.
Prior to beginning the migration process, please check that your license is correctly configured. It should reference "sites" and "machines", and not "nodes" and "limitednodes." Please expand the panel below for an example of a fully configured MES license with OEE, Recipe, SPC, Trace and Production on the license. If the MES modules on your License page in your Gateway Configuration do not look like this, please contact your Inductive representative and they will update your license if necessary.
You won't be alone if you decide to migrate an existing application. Our tech support and design consulting group can help you review the steps necessary. We also offer a discounted design consulting rate if you want us to be more involved in the migration. Contact us at firstname.lastname@example.org or (800) 207-5506 for more details.
Understanding the Differences Between OEE 1.0 and OEE 2.0
The following table highlights the main differences between the two modules to provide an idea of what may need changing and how to do it.
|Feature||OEE 1.0||OEE 2.0|
|Shift Management||Configured in the Production model.||Uses the Ignition Schedule Management component or tag path collector to manage and determine current shift.|
|Downtime reasons||Configured in the Production Model.||Configured in the OEE Equipment Manager component.|
|Real-time status||OPC Production Tags provided.||OPC Production Tags replaced with MES Tag Provider and Live Analysis.|
|Data Capture||Equipment status, production counts and additional factors only stored during an active run.||Equipment mode, status, production counts and additional factors only stored recorded continuously whether a run is active or not.|
|OEE Analysis||OEE Metrics calculated during run and stored in analysis tables.||OEE Metrics are calculated on demand and not stored in database tables, only raw values are stored for status and counts.|
|Downtime Detection||Key Reason only valid when primary cell is at head or tail of a production line.|
Key Reason detection available for a primary cell anywhere in the production line. The original Key Reason downtime detection method is not longer supported. Key Reason Cell Priority will be used in its place.
Remote Operator Reason Code SQL Tag is no longer used.
|Cell Groups||Cell groups can only consist of Parallel Cells.||Cell Groups can be used to create sub-lines, use parallel cells, initial reason or key reason. Cell groups can be nested.|
|Production Counters||Infeed, outfeed and waste counters configured at the line and cell level.||MES counters used for all production counts.|
|Data storage||Runtime data stored in tables in the runtime database and automatically purged. Final production data stored in analysis tables in the analysis database and is persistent.||Runtime database no longer used. All production data is persistent and stored in the Analysis database.|
|Product Codes||Product codes created using ProductCode, ProductCodeLine and ProductCodeProperty table components.||Product codes replaced with same Material Definition and Material Class objects as used by Track & Trace and created using the OEE Material Manager component.|
|OEE Production Settings||OEE production settings such as Schedule rate, Standard rate, package count, etc. configured in the outfeed counters and in the ProductCodeLineProperty table component.||OEE production settings such as Schedule rate, Standard rate, package count, etc. configured in the OEE Material Manager component and can be overridden by passing values through the tag collectors.|
|Scheduling||OEE Production runs scheduled using OEE Schedule View component.||OEE Production runs scheduled using the same MES Schedule View component as used by Track & Trace.|
|Work Order Management||Work Orders managed using the Work Order Table component.||Work Orders managed using the same MES Work Order Table component as used by Track & Trace.|
|Production Runs||RunUUIDs created for each production run.||Production runs use operations segments and have their own OperationUUID. Operations segments are automatically created by the OEE Material Manager whenever a product code is associated to a production line. Operations segments can be modified through scripting and with the MES Object Editor component.|
|Analysis||Analysis Selector and analysis controller components as well as scripting functions used to access OEE data.||MES Analysis Selector and MES Analysis Controller components replace the legacy components. Security now available to prevent unauthorized changes to Stored Analysis settings. SQL like filters can be used to return specific production data.|
|Reporting||Analysis controller and scripting functions used to provide dataset to reports.||New Analysis datasource available to report designer to access stored analysis settings.|
|Editing Production data||system.production.adjustRunData() scripting function available to adjust production counts. No method provided to adjust OEE availability data other than downtime reason code. No good way to add production run data after the fact if production run was not active.||MES Value Editor and scripting functions provided to add, edit and delete all production data.|
|Additional Factors||Additional Factors are defined only at the Line production item level.||Additional Factors can be defined at the Line and Cell production item level.|
Equivalent Scripting Functions
As OEE 2.0 now uses the same object model as Track & Trace, any scripting using the system.oee, system.production, system.production.utils and system.schedule libraries will need to be replaced. OEE 2.0 uses the system.mes, system.mes.analysis and system.mes.workorder libraries and MES Objects functions. The following is a listing of removed MES 1.0 scripting functions and their equivalent in MES 2.0.
- Schedule component palette has been removed as OEE scheduling now uses the same components in the Production palette as Track & Trace.
- OEE Downtime component palette has been replaced with the OEE Downtime 2.0 component palette.
- Production component palette now includes scheduling components, new MES 2.0 components and product code components have been removed.
Direct Database Queries
OEE 2.0 uses the same database schema as Track & Trace for configuration information and production data. Any direct SQL database queries to the OEE 1.0 Analysis or Runtime database tables must be replaced. All OEE 2.0 data can be accessed through Scripting Functions and MES Objects. There should be no reason to use direct SQL queries to the MES tables. Avoid doing so as much as possible to ensure future forward compatibility.
OPC Production Tags
OPC Production Tags for real-time OEE data have been replaced with the MES Tag Provider configured through Live Analysis settings. All OPC tags in the tag browser need to be removed and screens that bind to them will need to be modified. See Live Analysis Tags for more information.
How Configuration Data is Upgraded
Data is upgraded in three different areas:
- Production model settings are upgraded when the Platform 2.0 production model detects a production model is saved in serialization version 1. In MES 1.0, the entire production model is saved as one resource in the Ignition global project. In MES 2.0, each production item in stored as a separate resource in the Ignition global project. The OEE 1.0 settings that are transitioned over to the OEE 2.0, are first exported to temporary files. After the production model is converted, the OEE 2.0 values are added or updated based on the OEE 1.0 values saved in the temporary files.
- In OEE 1.0 downtime reason settings are saved in the production model. In OEE 2.0 downtime reasons are replaced by Equipment States are saved in the MES database. When the production model is upgraded, the downtime reason settings are saved to the Downtime_Reasons.cnf file located in the Ignition data/MES_Upgrade folder. The user can then import the downtime reason settings using the MES Legacy Import page on the gateway. This will read from the temporary file and create the appropriate Equipment State Class and Equipment State MES objects.
- Historical data from past OEE runs can be imported using the MES Legacy Import functions under MES Settings on the gateway.
The following configuration information will be automatically updated...
- State Tag Path for lines and cells will be copied from the existing State SQLTag to the appropriate State Tag Path collector.
- Downtime Detection Method will be created for the line only.
- Lines set to 'Key Reason' will be set to 'Key Reason Cell Priority'. All other detection methods will be translated directly.
'Key Reason' had some unusual behavior in OEE 1.0 and was deprecated being replaced by 'Key Reason Cell Priority' and 'Key reason Neighbor Priority'. If your current application uses the 'Key Reason' detection method, validation of the new detection method on the line should be validated as part of the migration process.
- All Cell Groups will default to 'Parallel Cells'.
- Lines set to 'Key Reason' will be set to 'Key Reason Cell Priority'. All other detection methods will be translated directly.
- Infeed, Outfeed and Reject Counters will be transferred over to MES Counters.
- All Waste Counters will become Reject kind MES Counters.
- Infeed Counters will become General kind Counters except for the one selected for Primary Infeed.
- Outfeed Counters will become General kind Counters except for the one selected for Primary Outfeed.
Units are no longer set in the counters and must be set using the OEE Material Manager.
- All counters transitioned over will be set to Roll Over mode.
- Downtime events are replaced with Equipment States. Because OEE 1.0 downtime reasons are duplicated for each line and OEE 2.0 Equipment states are consolidated into Equipment State Classes that can be assigned to multiple equipment items, during conversion identical downtime reason lists will be consolidated. The names will be in the Equipment State Class-x format. They can be renamed once converted. The Downtime Reason Description is not taken into consideration when checking for equality during consolidation. State mapping is as follows:
- If Record Downtime = False and Planned Downtime = False, then Type = Blocked
- If Record Downtime = True and Planned Downtime = False, then Type = Unplanned Donwtime
- If Record Downtime = False and Planned Downtime = True, then Type = Planned Downtime
- Record Downtime = True and Planned Downtime = True is invalid and not allowed in Platform 1.0
Modify Application to use new OEE Module Functions
- All OPC Production Server tags related to OEE will have to be remapped to new Live Analysis tags.
- Windows using OEE 1.0 components need to be refactored with new OEE 2.0 components.
- Shift Configuration
- Equipment Configuration
Equipment configuration can be automated with the Legacy Import tool as detailed below. At this stage you may simply want to add the components to the screen
- Product Definition Configuration
Product code configuration can be automated with the Legacy Import tool as detailed below. At this stage you may simply want to add the components to the screen
- Production Scheduling & Dispatch
- Production Order Execution
- Production Performance Analysis and Reporting
Import Configuration Information and Checklist
Now that you understand the differences between OEE 1.0 and OEE 2.0 and have prepared your tags and screens for the data migration, you are ready to import your legacy configuration information.
The upgrade process from OEE 1.0 to OEE 2.0 involves many steps that must be successfully completed. See Migrating from OEE 1.0 to OEE 2.0 for details on the upgrade process. Incomplete steps or errors encountered during upgrade may cause undesirable results. It is STRONGLY RECOMMENDED to backup the Ignition Gateway and relevant databases (configured under MES Settings on the Ignition Gateway) prior to importing. Upgrading to Sepasoft MES 3.0 Users should not attempt to upgrade from MES 1.0 directly to MES 3.0. Upgrade to MES 2.0 first and then upgrade to MES 3.0.
The upgrade process from OEE 1.0 to OEE 2.0 involves many steps that must be successfully completed. See Migrating from OEE 1.0 to OEE 2.0 for details on the upgrade process. Incomplete steps or errors encountered during upgrade may cause undesirable results. It is STRONGLY RECOMMENDED to backup the Ignition Gateway and relevant databases (configured under MES Settings on the Ignition Gateway) prior to importing.
Upgrading to Sepasoft MES 3.0
Users should not attempt to upgrade from MES 1.0 directly to MES 3.0. Upgrade to MES 2.0 first and then upgrade to MES 3.0.
- The time it takes to import historical production run data depends on the amount of production runs, additional factors, downtime events, etc.
- To import historical production run data, Running must be assigned the code of 1. This is how it was in OEE 1.0 by default.
- During import of downtime reasons, product codes or historical production runs, the database tables may be locked preventing live MES functionality from occurring.
- Import of downtime reasons, product codes, or historical production runs is an "all or nothing" operation. If there is an error, all data associated with the current import will be rolled back.
Historical Production Data Mapping
Details of OEE 1.0 data formatting after legacy import.
The production data in the following tables is converted as shown in the table below.
|OEE 1.0 Tables||Conversion Process|
The configuration for additional factors in the Production Model is the same between OEE 1.0 and OEE 2.0. However, the history of additional factory values has changed from the horizontal table format to the vertical table format.