This document summarizes a thesis presentation on designing an expert system for monitoring and managing web-based industrial applications. The presentation covers problem statements and objectives, a case study of an industrial production line, designing a web service monitoring system using XML schemas, implementing the expert management system using a knowledge base and rules engine, and conclusions and future work. The goal is to integrate old automation technologies with modern web service and information technologies using a smart monitoring and management system.

1. TTE-7906, Machine Automation Thesis Presentation Seminar
Design and Implementation of an Expert
System for Monitoring and Management of
Web-Based Industrial Applications
Prepared by
Ahmed Sadik
Degree Programme in Machine Automation
Major: Factory automation
Minor: Microsystems
Supervised By
Dr. Andrei Lobov
Funded by
TUT - FASTory lab ( PlantCockPit project )

2. TTE-7906, Machine Automation Thesis Presentation Seminar
Contains
Problem statement – purposed solution and thesis work
The case study – FESTO MPS 500
Web service definition and advantages
Designing of web service ( XML schema – WSDL )
Results of the web based monitoring system
Designing of an expert management system
Human experts in from of KPIs ( Key Product Indicators )
Implementation of the Expert management system
Conclusion and future work - References
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3. TTE-7906, Machine Automation Thesis Presentation Seminar
Problem statement and work objective
• Integrating the old automation technologies which exists in shop floor to the current factory
information technology, specifically web service technology without destroying the shop floor
infra-structure or interrupt the production process
• Processing the information obtained from web services using a smart management system
Purposed solution and thesis work
• Adding a new controller which compatible with the
old technologies and able to implement the web
service technology
• Applying the recommendation of ISA-95 model
at layer two and three
• Designing generic XML events based on analogy with CAMX standard to monitor the system in
layer two of ISA-95 model
• Defining the convenient key product indicators – KPIs – in a generic way to fit most of similar
production lines to our case study
• Translate those KPIs in form of drool software rules, for management of the system in layer
three of ISA-95 model
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4. TTE-7906, Machine Automation Thesis Presentation Seminar
The case study – FESTO MPS 500
• Distributing unit
• Testing unit
• Handling unit
• Processing unit
• Assembling and robot unit
• AS/RS20 warehouse
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5. TTE-7906, Machine Automation Thesis Presentation Seminar
Designing of a web service monitoring system
A web service is a software system designed to support interoperable
machine-to-machine interaction over a network. It has an interface
described in a machine-processable format (specifically WSDL). Other
systems interact with the Web service in a manner prescribed by its
description using SOAP messages, typically conveyed using HTTP with an
XML serialization in conjunction with other Web-related standards
XML web service
Why example
1- Self-contained application and independency of the language of the operating system
2- Self-describing application
3- Encapsulated, modularity, integrity and expandability
4- Interoperability
5- Discoverability - Dynamic language
6- Open source and standard language
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6. TTE-7906, Machine Automation Thesis Presentation Seminar
Designing of the XML schema based on CAMX standard
WP_ID
Station_ID
Station_ID
Time_Stamp Time_Stamp
1- Manual_Start 1- Black
2- Manual_Reset
Labour WP WP_Color 2- Non_Black
Labour_ID
3- Manual_Stop
1- Defected
4- Alram_Clear WP_Quality
Labour_Action 2- OK
5- Error_Clear
6- Warning_Clear WP_Status 1-In_Processing
7- UnBlock_Clear
2-Transfering_IN
8-UnStarving_Clear Station 3-Transfering_Out
4- Pause
5-No_Work_Piece
Station_Status Event_Source_Component Station_Event Time_Stamp Station_ID
1-Processing 1- Alarm/Alarm_Cleared
2-Waiting 2- Warning/Warning_Cleared
3-Ready 3-Error/Error_Cleared
4-Idle 4-Blocked/UnBlocked
5-Started 5-Starving/UnStarving
6-Stoped 6-HeartBeat/HeartBeat_response
7-Rested 7- No_Event
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7. TTE-7906, Machine Automation Thesis Presentation Seminar
Designing of the WSDL document
Types a container for all the data type using
standard way such as XML schema
Message an abstract, typed definition of the data
being communicated
Operation an abstract description of an action
supported by the service
Port Type an abstract set of operations supported by
one or more endpoints
Binding a concrete protocol and data format
specification for a particular port type
Port a single endpoint defined as a combination of a
binding and a network address
Service a collection of related endpoints
Implementation of web services on our case study
The S1000 is a smart RTU device which offers
process control capabilities, as well as a
Web-based Human-Machine Interface (HMI),
support for WebServices,
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8. TTE-7906, Machine Automation Thesis Presentation Seminar
Web service monitoring system results
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9. TTE-7906, Machine Automation Thesis Presentation Seminar
Designing of an expert management system
Expert
Expert system shell
Knowledge Knowledge Reasoning User
Base Base engine Interface
User
Expert Systems (ES): A computer program that contains a knowledge base and a set of
algorithms or rules that infer new facts from knowledge and from incoming data. An expert
system is an artificial intelligence application that uses a knowledge base of human expertise to
aid in solving problems. The degree of problem solving is based on the quality of the data and
rules obtained from the human expert. Expert systems are designed to perform at a human expert
level.
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10. TTE-7906, Machine Automation Thesis Presentation Seminar
Human experts in from of KPIs ( Key Product Indicators )
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11. TTE-7906, Machine Automation Thesis Presentation Seminar
Implementation of the Expert management system
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12. TTE-7906, Machine Automation Thesis Presentation Seminar
Conclusions
• ISA 95 model can fit modern automation system designs
• CAMx standard is meant to be for exchange data among manufacturing equipment and
applications on the electronics manufacturing floor. However still can be used as a reference for
creating generic XML schemas for other applications
• Web service technology is suitable technology to upgrade the old existing automation system
• Drools is a suitable rule engine for building an expert system for a web based industrial system
Future work
• Providing more graphical user interface (GUI) for user for both monitoring and management
system
• Tasting our management system with the XML messages coming from the machines not from
Fiddler
• Searching for other generic KPIs for the other elements within the project and translate them to
drool rules
• Expand the rules due to the new experiences of the case study
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13. TTE-7906, Machine Automation Thesis Presentation Seminar
References
• K. Darlington, The essence of expert systems, Prentice Hall, 2000.
• B. Q. a. H. B. Gooi, “Web-Based SCADA Display Systems (WSDS),” IEEE TRANSACTIONS
ON POWER SYSTEMS, vol. 15, no. MAY 2000, pp. 681-686, 2000.
• I. c. R. A. GE Fanuc Ameriicas, “Standards for Manufacturing Systems Integration,” 2006.
• ANSI, “ISA95.00.03 - Enterprise-Control System and Integration part 3: Model of Manufacturing
Operation Management,” 2005.
• S. M. W. Deon Reynders, Practical Industrial DataCommunications - Best Practice Techniques,
IDC Technologies, 2005.
• F. D. GmbH, CIROS ADVANCED MECHATRONICS, Germany , 2008.
• T. K. R. S.-J. S. S. W. Ueli Wahli, WebSphere Version 6 - Web Services Handbook
Development and Deployment, Germany : IBM, July 2005.
• O. Z. Olaf, “Architectural Decisions as Service Realization Methodology in Model Methodology
in Model--Driven SOA Driven Construction,” in 4th IEEE European Conference on Web
Services, Zurich, Switzerland, December 4 – 6, 2006.
• S. H. Seungjin Choi, “WS-BPEL Monitoring System,” International Journal of Web Services
Practices, vol. 6, pp. 18-20, 2011.
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14. TTE-7906, Machine Automation Thesis Presentation Seminar
Questions ?
Thank you!!
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