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Procedia CIRP 107 (2022) 1329–1335
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55th CIRP Conference on Manufacturing Systems
MES Dynamic interoperability for SMEs in the Factory of the Future
perspective
Bilal Shabbir Chohan*, Xun Xu and Yuqian Lu
Department of Mechanical Engineering, University of Auckland, 1010, New Zealand
* Corresponding author. Tel.: Tel.: +64 9 373 7599; Fax: +64 9 373 7479. E-mail address: bcho780@[Link]
Abstract
Small and Medium-sized Enterprises (SMEs) hold a significant proportion in the economy and more than half of employment worldwide.
Nowadays, many SMEs are embarking on a digital transformation journey by embracing and deploying the Fourth Industrial Revolution (a.k.a.
Industry 4.0) technologies with a vision of the “Factory of the Future”. Factory of the future aims to enhance production by making improvements
in three dimensions: plant structure, plant digitization, and plant processes, which cut across many key function areas of Manufacturing Execution
Systems (MES) such as management of product definitions, resource scheduling, order execution and dispatch, production analysis, product
quality, and materials track and trace. The technological shift with the Factory of the Future, e.g., the adoption of information, communication,
and networking technologies in the form of the cyber-physical production system (CPPS) in order to manage interoperability at the factory’s
functional levels in real-time, demands a fresh look at the functional aspects of MES as well as the interplays between MES and an enterprise
resource planning (ERP) system and a process control system (e.g., SCADA). The Factory of the Future may lead to hierarchical changes in MES
byways of redesigning the value chain for dynamic production and mass personalization scenarios. Deployment of the responsive and adaptive
value chain in MES is still state-of-art-issue. The authors will address dynamic interoperability between modular functionalities for end-to-end
integration and consider microservices scenarios to form a service-oriented architecture that supports the part of MES in the responsive and
adaptive industrial value chain. Primary modules of the manufacturing execution system have been identified from ISA-95 standards and
demonstration of end-to-end integration via OPC-UA server/client and PubSub mechanism contributing to the execution of business and
manufacturing functions. Each element or activity runs in its own process and provides a microservice; each microservice communicate with
other services and form a service-oriented architecture for MES. Finally, a universal framework solution has been proposed for dynamic
interoperability, which intends to upgrade the value chain and networking of a conventional industry towards a factory of the future.
© 2022 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license ([Link]
Peer-review under responsibility of the International Programme committee of the 55th CIRP Conference on Manufacturing Systems
Keywords: Factory of the Future; Industry 4.0; Value chain; Interoperability; Manufacturing Execution System; ISA-95; RAMI4.0; CPPS
1. Introduction enterprises (SMEs) [1]. Compared to the large enterprises,
SMEs contribute to more than 90% of the business population,
The Factory of the Future is an ongoing vision rather than a 60-70% of employment, and 55% of GDP in the World
one-time project. It brings the world to the current 4th Industrial economies [2]. Large companies handle the complexity more
Revolution, also known as Industry 4.0 (I4.0), enabled by the comprehensively using methods and tools of interoperability
Internet of Things (IoT), Cyber-Physical System (CPS), and management on the advanced level. However, the working
cloud computing-related technologies, which is further refined principles of SMEs are based on complex systems, great
as Industrial Internet of Things (IIoT) and Cyber-physical variety, and low volume ignited by personalized demands. In
production systems (CPPS) in the industrial domain. The the IIoT and CPPS environments, less research focus has been
corporate focus of Industry 4.0 is Small and medium-sized observed for SMEs, although the whole industrial value chains
2212-8271 © 2022 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license ([Link]
Peer-review under responsibility of the International Programme committee of the 55th CIRP Conference on Manufacturing Systems
10.1016/[Link].2022.05.153
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1330 Bilal Shabbir Chohan et al. / Procedia CIRP 107 (2022) 1329–1335
mostly rely on SMEs [3]. In addition, SMEs play a significant customers’ customized and personalized demands to the shop
role and provide value-oriented solutions to the requirements floor back-and-forth. To accommodate the autonomous
and needs of society. The current challenge for SMEs to information flow in end-to-end integration from the shop floor
transform to the CPS-based automation paradigm is the digital up to the business process level is still a current challenge.
modularity and interoperability during end-to-end integration in Enterprises are adopting service-oriented infrastructure based
real-time. Regarding digital transformation technologies, nine on a cross-enterprise service landscape [11]. These solutions
pillars of technological advancement for Industry 4.0 have been support a strong collaboration between business and
envisaged, i.e., industrial internet of things, autonomous robots, manufacturing activities. The transformation of the ISA-95
simulation, big data and analytics, horizontal and vertical automation hierarchy to CPS-based service-oriented
system integration, cybersecurity, additive manufacturing, automation (Fig. 1) indicates the connection and collaboration
cloud, and augmented reality [4]. These advanced technologies
have equipped with the integration of assets, cloud computing,
software and hardware applications, machine-machine or
human-machine interfaces, and edge devices or components
such as RFID, sensors, actuators, etc. (embedded in assets).
Various solutions are available for digitization, including
computerization and connectivity of the assets, and
visualization [5,6]. However, autonomous response and self-
optimization between industrial functional elements in
production management (production planning, scheduling, and
controlling) are still at the development phase. Researchers and
enterprise professionals are looking for the service-orient
architecture [7-10]. Customizing value-added service-oriented
infrastructure according to the enterprise need is challenging
Fig. 1 Cloud-base composition of cyber-physical services [10].
due to proprietary (ERP, MES, and more) software solutions
and ultimately facing vendor lock-in during configuration
of each industrial element out-of-the-box, regardless of
[11,12]. On the other side, the real value in the logistics system
hierarchy levels. Therefore, the factory of the future demands
can be obtained when it is connected with the actual shopfloor
non-hierarchal communication and software-based value-
information. CPS-based automation for smart manufacturing
added system to increase production efficiency and process.
redefines the value chain to quickly respond in dynamic
The main components of CPPS in a distributed manufacturing
production, mass personalization, and optimize lead time in
environment defined by RAMI 4.0, play a significant role in
individualized demands. The authors consider the part of
systems integration, i.e., Controllers, HMIs, IIoT connectivity,
manufacturing operation and control information from the
Cybersecurity, and Digital Twins [13,15]. In addition, the new
industrial value chain, attempt to address interoperability in
industrial world perspective emphasizes non-hierarchical value
dynamic scenarios, and propose a universal framework
chain connectivity (Fig. 2). RAMI 4.0 model is an ideal
effective in establishing manufacturing information systems.
The study was initiated by reviewing selective pieces of
literature, the RAMI 4.0 model [13], ISA-95 (aka IEC/ISO
62264) standards [14], and case studies in the respective field.
The second section provides a literature review. The third
section demonstrates the understanding of interoperability
based on microservices for the next-generation business
management, which is followed by the fourth section
presenting the framework solution for dynamic interoperability.
The paper concludes at the end.
2. Literature review
Industry 4.0 is urged by dynamic market requirements and
demands and the recognition of new technologies. Latter has
brought industrial development to today’s highly automated
facilities, from the early adoption of mechanical systems to
Cyber-physical systems. However, performance dimensions
such as great variety, low volume, optimum cost, productivity
and quality, optimum utilization of energy and resources,
flexibility, and reconfigurability in production systems demand
manufacturing processes to react flexibly and optimally to Fig. 2 The new World factory hierarchy RAMI 4.0 [22]
changing conditions. Real-time information flow must be
responsive and adaptive in the entire process value chains from example of service-oriented architecture, in which conventional
hierarchical complex processes break down into easy-to-grasp
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Bilal Shabbir Chohan et al. / Procedia CIRP 107 (2022) 1329–1335 1331
packages, and all elements and IT components are application is a single package based on predefined lock-in
interconnected via network to achieve flexibility in production coding and is usable within set parameters. It consists of
systems. Functions are distributed through the network, and indivisible units and is dependent on the sharing of the same
network mesh assists in crossing the company boundaries, resources of machine such as memory, databases, or files.
which provides interactive tools for all enterprise participants Modules in monolithic architecture are unable to execute
to communicate with each other regardless of hierarchy. In operations independently (Fig. 4), considering value-added
addition, products in CPPS are part of the network. The
microservice architecture supports the infrastructure of the
RAMI model and helps to further break down the domain
services into small and independent services. Fig. 3 depicts the
Fig. 4 Monolithic vs Microservices architecture (image is modified from
[Link]
factors, the monolithic system is strongly coupled with
overlapping responsibilities. In contrast, microservice
architecture can perform unique services that are independently
Fig. 3 Services integration into the Cloud responsible. It is a distributed application in which all its
modules are microservices, message contracts using XML
services integration offered by different automation levels. Schema, and WSDL allows microservices to communicate
Elements in each level of automation defined by ISA-95 are exclusively and a combination of independent building blocks
interconnected and provide services into the cloud, regardless compose the structure of the systems. Through its loosely
of the pyramid hierarchy, which is enabled by opensource, and coupled lightweight communication mechanism, small suites of
IIoT applications and platforms that lead to feasibility for services build up larger applications and communicate via API
management, monitoring, and controlling via web services endpoint/HTTP protocols. In addition, microservices
based ubiquitous HMIs. Each system or device’s functionalities architecture assists in deploying flexible, maintainable, and
can be offered as one or more services of various complexity, scalable software applications to decompose the large system
hosted in the cloud, and composed by other (potentially cross- into sets of independent services with various business
layer) services [10], by using technologies such as functional capabilities [8]. For instance, microservices-based
endpoint/TCP/IP, HTTP, XML, SOAP, and WSDL. In MES breakdown the core components (such as production,
addition, the standards and relationship pattern between maintenance, quality, and inventory) and resources into their
business activities, objects, and attributes provided by ISA-95 products. These elements exchange the information of services
[12] aids in customizing an enterprise's own virtual plant through synchronous communication for real-time stream and
structure in XML semantics, while open-source information asynchronous for batch processing. OPC UA connections
and communication protocol such as OPC-UA is found to be an support component and object-based modeling, storing the
essential tool to achieve information and communication
aspects in the integration by its publishing and subscribing
mechanism. Although, synchronizing these elements to form a
start-of-art solution for SMEs, opens the door to
implementation challenges due to complex applications and
manufacturing systems.
3. Interoperability based on microservices
SMEs in the Factory of the Future vision have to deal with
the obstacles of autonomous interoperability between business,
manufacturing functionalities and distributed control systems.
While dynamic demands set up new dimensions for plant
structure, process, and digitization in the Industry 4.0
environment, most legacy software stakes in the production
Fig. 5 High-level concept of the MES (as a service) architecture. [23]
system are based on monolithic architecture. The monolithic
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plant element models into the raw data storage in distributed operations and enterprise functions. OPC UA client feature
databases, maintaining libraries and accessible through extracts the data from the server hub for controlling purposes,
AddressSpace endpoint URL or TCP/IP, persistent repositories, IIoT and open-source platforms assist in customizing need-
and logging enabling data streaming via message-oriented based HMI dashboards. Next-generation service-oriented
(such as MQTT, AMQP, Apache Kafka) technologies. An architecture based on microservices is envisioned to create
example from a recent similar study is presented in Fig.5 [23]. microservices suites to form applications in a modular manner
The edge components such as sensors, devices, machines, etc. achieving digital modularity at functional business levels.
are the primary source of data in CPPS, these elements publish These small independent suites then communicate within
their capabilities and provide information such as element applications of different domains (Fig. 7). RFID middleware
description, variables, and variables’ status [23], which can be
invoked through parametrized functions, function call initiates
the instances, execute the related tasks and event-triggered
reports assist in tracking execution advancement. Fig. 6 shows
Fig. 7 Microservices-oriented PubSub dynamics
services assist data collection and acquisition across the factory
[6], feed enterprise information systems with real-time data for
scheduling, monitoring, and control purposes, including
functions in manufacturing operation management. Machine-
to-machine framework solves the interoperability between
machines [19] and intelligent shopfloor based on smart machine
Fig. 6 Interoperability based on SOA agents, service-oriented technologies, and IIoT devices enhance
the self-organizing and self-adapting capabilities at the
a brief demonstration of information and communication based production process level [20]. However, management of
on services-oriented architecture from the shop floor to the resources for dynamic production scheduling, controlling, and
business level. From bottom to top, the shopfloor assets/devices execution require conceiving paradigms such as the
layer represents the production process. The assets, equipment, applications-machines matrix communication framework (Fig.
and devices are equipped with edge components such as RFID, 8). Information of customers' order breakdown into the
NFC, sensors (including camera as a sensor), actuators, and
drivers. These edge components are connected with fieldbuses
or I/O network mediators to communicate within IIoT devices.
OPC UA and message-oriented technologies as a middleware
provide the support for information and data exchange,
comprises client and server relationships to subscribe and
publish the production data based on XML schema, generated
from edge components. The individual server serves as a
microservice and publishes data from individual edge
components that create metadata into the database. Similarly,
information flow at the functional level follows the same
pattern. Production orders received from the customers
assigned a unique ID from the initial process in the business
applications, whole supply chain information related to that
order is identified with the same unique ID stored in RFID/NFC
Fig. 8 Applications-machines matrix communication framework
tags, QR/BAR codes, or input devices attached with the carrier.
These edge devices facilitate the workstations for data
compatible language elements via webshops or client portal
exchange and information updates between machine-to-
(front-end) provide the services for product specification
machine, machine-to-application, and application-to-
information further encoded with the XML schemas in the
application communication to perform manufacturing
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backend, forming data-set, discover and develop mapping database (Fig.9). The MES mechanism behind the cockpit is the
through edge computing detection like algorithms [21]. The
factory capability information is further identified by nodes
already available in the form of microservice into the
addressSpace in the database, extract the data for matching to
schedule, and process the next step. Applications of MES core
components such as Production, Maintenance, Inventory, and
Quality facilitate with the acknowledgment of order execution
details and assigning the tasks according to the information
received by ERP applications and allocate the resources e.g.,
personnel, equipment, material, and physical resources
(including energy). according to the product definition, recipe,
and process rule/routes. Applications of SCADA/DCS
comprises on controlling ability of backend metadata composed
of individual (OPC-UA) servers published by the resources, the
message-oriented middleware services, and WSDL can GET,
POST, UPDATE, PUT or DELETE the information into the
database based on real-time allow to provide access to any
application to communicate with each other and read, write or
update any information during the production process.
Applications of IIoT devices allow computing over the internet
and assist in developing user-friendly dashboards for HMIs.
4. MES Framework solution for dynamic interoperability Fig. 9 MES iceberg
The manufacturing execution system is not just limited to actual workout that reforms the system, required to define and
specific software applications; it is an approach to form a model plant structure on a microservices perspective to
system for executing manufacturing. The purpose of virtualize the existing plant in semantics, the best practices,
MES/MOM in enterprises are recipe control, managing which include:
workflows, optimizing utilization of resources, and improving
production process and efficiency. The majority of MES • Domain’s functions model defines all the functions in a
applications deal with statistical data for scheduling, domain
controlling, and monitoring purposes. It connects the workers, • Functions of interest are defined in detail
machines, material, equipment, and workstations across the • Defining Information flow of interest between functions of
enterprises. Legacy MES system applications are predefined interest
with extra overlapping modules. Smart manufacturing in CPPS • Category of information defines relationships with activity
environment demanding to redefine MES ISA-95 models and categorizes the source of information
functionalities, e.g., production definition management; • Information definitions include information models
production resources management; detailed production • The information model is defined with resource models
scheduling; production dispatching; production execution (personnel, equipment, material, and physical assets) and
management; production tracking; production data collection; interactive models (operation capability, operation
production performance analysis. These functions are the same definition, operation schedule, and operation performance)
in the category of MES core components such as Production,
Maintenance, Inventory, and Quality [14]. MES design MES is required to assign the responsibilities independently
principles should be based on IIoT connectivity, distributed to each element in the manufacturing facility to cope with
control, digital modularity, and digital twin [12]. The core idea dynamic demand, which is changing dramatically. Usually,
behind the CPPS is non-hierarchical communication. The conventional industries are compatible to execute uniform
envisioned service-oriented MES based on microservices production orders such as mass production, few industries are
seems compatible to handle dynamics of information in real- capable of producing mass customization with adding
time, connect IIoT devices, multi-agent integration, and assist predefined planning, scheduling, and execution facilities but
with real-time data for virtual manufacturing. The MES cockpit the MES software is placed on the same database. Although,
mainly consists of graphical user interfaces for monitoring and satisfying customers with personalized demands require huge
controlling purposes for stakeholders. Overall equipment change over cost or disturbance in the existing set-up due to
efficiency (OEE), Keep performance indicators (KPI), and limitation of proprietary software applications, central MES
reporting tools assist in performance analysis and decision system, and fixed supply chain. Considering distributed
making to deploy optimum planning and scheduling of manufacturing system to meet the individualized demands,
resources to execute production order and maintain enterprise need each element in the production facility to be responsible
facilities; this can be achieved from the modeling of plant for executing its task. The same applies to MES. However,
elements in XML semantic and forming library into the distributed MES needs to face interoperability and digital
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modularity issues. Microservices architecture is capable of interoperability and digital modularity during end-to-end
dealing with both challenges. Its working principle is based on integration at the functional level. The authors emphasize
small suites interacting with multiple agents and databases. Fig. microservices architecture and present an understanding of
10 demonstrates the framework solution to develop the interoperability based on microservices. Currently, researchers
are focusing on service-oriented architecture to integrate
industrial elements regardless of hierarchy. However,
flexibility and autonomous response in changing conditions and
meeting the dynamic demand, are required blocks of services
further breakdown into small suites to achieve value-added
integration. Transparency of the information requires the
backend working to develop a plant library on a modular
perspective of all available resources. Networking and
communication technologies aid in interconnection and
communicating within all resources of a company. This can be
achieved through deploying applications-machines matrix
communication framework. OPC UA and message-oriented
protocols further facilitate data mapping, data feeding, and data
acquisition in real-time, assisting in product definition,
scheduling, and execution. Lastly, a universal framework for
dynamic interoperability has been proposed that supports the
dynamics of the demands.
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