Standardize Legacy Machines
Future-Proof Your Factory

POOL provides a standardized framework for executing production orders across any ISA-88-compliant Process Cell.

Leveraging on OPC UA, POOL gives end users the freedom to integrate best-of-breed equipment and controls' technology.

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The implementation of POOL was performed at Philip Morris International on legacy machines leading to substantial improvements and prompting a global roll out.

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POOL features follow:

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1. Production Order Management

• Release/Unrelease Production Orders: Ability to release or unrelease production orders (POs) to/from the Process Cell, a.k.a. Production Line.
• Assign/Unassign Production Orders: Assign POs to specific Units or unassign them when no longer needed.
• Start/Stop Production Orders: Start or stop POs on specific Units, with support for manual and automatic triggers.
• Complete Production Orders: Mark POs as complete when production is finished, with automatic completion based on predefined conditions.
• Abort Production Orders: Abort POs in case of errors or interruptions, transitioning the state machine to an aborted state.
• Get Production Order Information: Retrieve detailed information about POs, including material lists, datasets, and production status.

2. State Machine Management

• Production Order State Machine: Manage the lifecycle of POs through states such as Released, Assigned, Started, Executing, Completing, Aborted, and Stopped.
• Unit State Machine: Manage the state of individual Units through states such as Assigned, Executing, Completing, Aborted, and Stopped.
• Automatic State Transitions: Support for automatic transitions between states based on conditions such as AutoStart and AutoComplete settings.
• Manual State Transitions: Allow manual intervention to transition states (e.g., starting, stopping, or aborting POs).

3. Automation Features

• AutoStart: Automatically start production on a Unit when upstream conditions are met (e.g., when the upstream Unit is running the same PO).
• AutoComplete: Automatically complete production on a Unit when downstream conditions are met (e.g., when the downstream Unit is complete or has a different PO).
• AutoStop: Automatically stop production on a Unit when conditions are met (e.g., when no more input materials are available).

4. Data Flow and Integration

• OPC UA Compliance: POOL is OPC UA compliant, enabling seamless integration with OPC UA servers and clients.
• Dynamic Machine Module Discovery: POOL dynamically discovers Units from the connected servers, reducing configuration effort.
• Data Flow Orchestration: POOL orchestrates data flow between Units and higher level systems.
• Non-OPC UA Payload Handling: Support for handling non-OPC UA payloads (e.g. MOM/MES payloads) alongside OPC UA payloads.

5. Material and Inventory Management

• Material List Management: Retrieve and manage material lists associated with production orders.
• Inventory Tracking: Track inventory of finished goods, semi-finished goods, and by-products.
• Material Loading/Unloading Points: Manage material loading and unloading points for each Unit ensuring correct material flow.

6. Event Handling and Messaging

• Event Generation: Generate events for material consumption, dispensing, and production status changes.
• Message Publishing/Subscription: Publish and subscribe to messages via MQTT or other protocols for real-time communication.
• Error Handling: Provide feedback and error handling for failed operations (e.g., missing resources, invalid states).

7. Central Visualization and Control

• Central Visualization (CV) Integration: Expose PO states and variables to a central visualization system for monitoring and control.
• Read-Only PO Variables: Expose read-only PO variables (e.g., status, assigned POs) via OPC UA for external systems.
• Event Exposure: Expose events when POs change state (e.g., released, assigned, started, aborted).

8. Persistence and Recovery

• PO Persistence: Persist production order data to rebuild the status in case of service downtime.
• State Recovery: Recover the state of POs and machine modules after a service restart or failure.

9. Multi-PO Handling

• Continuous Production: Support for continuous production mode, allowing interleaving of POs across multiple machine modules without interruption.
• Interleaving POs: Support for interleaving POs in continuous production modes, allowing seamless transitions between different POs.

10. Micro-Service Architecture

• Stateless Design: POOL is designed as a stateless micro-service, making it robust and less prone to getting stuck in corner cases.
• MQTT Integration: Subscribe to MQTT topics for receiving POs and publish events for logging and monitoring.

11. Diagnostic and Feedback

• Execution Feedback: Provide detailed feedback on the execution of commands (e.g., success, failure, error codes).
• State Machine Diagnostics: Expose state machine transitions and conditions for diagnostic purposes, especially when AutoStart or AutoStop is enabled.

12. Compliance and Standards

• TMC Compliance: POOL is compliant with TMC standards, ensuring interoperability with TMC units and systems.
• ANSI/ISA-S88.01-1995 Compliance: Support for batch control standards, especially in handling WIP (Work in Progress) containers and storage units.

13. Customization and Configuration

• Configurable Units: POOL can be configured to work with any number of Units, as defined in the Aggregation Server.
• Recipe Parameter Mapping: Map recipe parameters from MOM/MES to TMC datasets, ensuring correct machine settings for each PO.

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CTA: Consult about your needs

The OPC Foundation releases for public use Version 2.0 of the OPC 30060 OPC UA Companion Specification for Tobacco Machine Communication (TMC) Joint Working Group.

Building on the strengths of version 1.0, version 2.0 extends the TMC OPC UA information modeling scope to the tobacco Primary Process including Kitchen Preparation, Secondary Make and Pack including Reduced-Risk Products (RRP) and Non-Tobacco Materials, NTMs.

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OPC 30060 v2.0 introduces the following new interoperability features:

1. Production Order Orchestration Layer:
   
   • Orchestration of Production Orders: coordinates production orders accross MachineModules in a Production line, a.k.a. Process Cell, compliant with ANSI/ISA-88.00.01-2010 Physical Model
   • Production Order Retention: automatically cleans up production orders when complete;
   • External Application Integration: acts as an external application interactig with Machine Modules but not directly implemented by them.
   • State Management: clearly exposes the state of production with ad hoc state machines
   • Interaction Logic: clearly defines how machines interact with one another to execute a production order. The logic is vendor and OEM independent.
   • Material Flow Control: specifies material sources and destinations for material routing during order execution.

Aleph releases FlexServer, the first TMC compliant OPC UA server including Historical Access (OPC10000-11) with  with connectors for legacy equipment (Hauni VHK, GD aHMI REST). Aleph FlexServer includes APS, AGS, PSM.

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Aleph FlexServer features follow:

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Core Features

1. Native TMC2.0 OPC UA Server:
   • Fully configurable via local files for easy roll-out.
2. Three-Layer Architecture:
   • Aleph FlexServer Core: The core TMC2.0 OPC UA Server application.
   • Aleph FlexServer Data Providers: Project-specific functions for executing methods and generating events.
   • Aleph FlexServer Configuration Connectors: Functional calls orchestrating the Core and Data Providers.
3. Multiple Deployment Options:
   • Run as a Desktop Application.
   • Run as a Windows Service.
   • Run as a Docker Container.
4. Data Connectors:
   • Supported Protocols:
     • Beckhoff ADS: Connects to Beckhoff systems supporting ADS protocol v2.1.1.
     • Siemens S7-Ethernet: Connects to Siemens CPU 200/300/400/1200/1500 series.
     • Hauni VHK: Connects to HAUNI machines featuring VisuHost protocol.
     • OPC XML-DA: Connects to systems exposing OPC XML-DA v1.01.
     • OPC UA: Connects to systems exposing OPC UA servers implementing DataAccess Server Facet.
     • Modbus TCP: Supports Modbus TCP protocol.
     • GD aHMI: Connects to GD aHMI systems.
   • Refresh Rate: Minimum 500ms.
   • Mapping Configuration: Schema-based JSON files for static and dynamic values, with support for formulas to expose conditioned values.
   • Maximum Connectors: Up to 8 connectors in total.
5. Start-up Configuration:
   • Configurable via XML file or environment variables.
   • Supports settings for data storage, logging, OPC UA endpoints, security, and more.
6. Users and Roles Management:
   • Supports Anonymous and User/Password authentication.
   • Configurable via XML files (FlexServerUserConfiguration.xml and FlexServerUserRoleConfiguration.xml).
7. Data Providers:
   • NotSupportedDataProvider: Returns a BadNotSupported status code.
   • ValueDataProvider: Provides a static value.
   • InMemoryValueDataProvider: Stores values in memory (not retained after restart).
   • JsonFileValueDataProvider: Stores values in a JSON file (retained after restart).
   • NoSqlDataProvider: Stores values in a local NoSQL database (retained after restart).
   • DataSourceValueDataProvider: Provides values from a specified data source and address.
   • DataSourceExpressionDataProvider: Provides values based on expressions calculated from input addresses.
   • DataSourceTotalizerDataProvider: Computes the total of values from a specified address.
   • DataSourceRateDataProvider: Computes the rate of values from a specified address.
   • ParentObjectPropertyValueDataProvider: Provides values from parent object properties.
   • EngineeringUnitDataProvider: Provides EUInformation values based on unit of measure.
   • StopReasonListDataProvider: Provides StopReasonList values from a CSV file.
   • DataSetListDataProvider: Provides DataSetList values from a CSV file.
   • DatasetDataProvider: Provides DataSet values based on DataSetList definitions.
   • DataSourceValueThresholdSelectorDataProvider: Maps values to thresholds.
   • StructureValueDataProvider: Combines values from other DataProviders into a structured value.
8. Method Implementation Providers:
   • Default implementations for TMC type methods.
   • Configurable via JSON files.
   • Supports MethodDataProviders for executing logic in underlying systems.
   • Methods can be configured to ignore the MachineModule.Remote setting.
9. Event Providers:
   • DataSourceDowntimeEventProvider: Generates DowntimeLogType events based on state changes.
   • TriggerEventProvider: Abstract provider for triggering events based on boolean values.
   • IntegrityRejectedMaterialEventProvider: Generates events for rejected material.
   • LoadingPointUnloadedEventProvider: Generates events when a loading point is unloaded.
   • MaterialConsumedEventProvider: Generates events when material is consumed.
   • MaterialDispensedEventProvider: Generates events when material is dispensed.
   • MaterialUnloadingRequiredEventProvider: Generates events when material unloading is required.
   • NewPresentedMaterialEventProvider: Generates events when new material is presented.
10. Default Logic for ObjectTypes:
    • MachineModuleConfigurationType: Generates events for changes in StopReasonList, RootCauseList, and RootCauseGroupList.
    • MachineModuleLiveStatusType: Generates events for state changes and populates alarms based on CSV files.
    • MachineModuleProductionType: Generates events for production status changes.
    • MachineModuleSetupType: Generates events for dataset changes and maps files to OPC UA documentation folders.
    • MaterialLoadingPointType: Generates events for material consumption and dispensing, and provides historization for key variables.
    • MaterialOutputPointType: Generates events for material production and provides historization for key variables.
    • MaterialRejectionPointType: Generates events for material rejection and provides historization for key variables.
    • MaterialStorageBufferType: Provides historization for loading and unloading rates.
    • DefectDetectionSensor: Generates events for detection mode changes and defect detection.
    • SensorFunction: Generates events for detection mode changes.
    • DefectReason: Generates events for detection mode changes and defect detection.
    • ProcessItem: Provides historization for process variables and computes aggregates (avg, std, max, min, total).
    • ProcessControllern: Provides historization for process control variables and implements logic for remote control.
    • ProcessControlLoop: Implements watchdog logic for process control loops.

Additional Features

1. Historization:
   • Built-in historization for key variables across various object types (e.g., MaterialLoadingPointType, MaterialOutputPointType, ProcessItemType, etc.).
   • Supports retention periods for historical data.
2. Aggregates Calculation:
   • Automatically computes aggregates (avg, std, max, min, total) for process variables.
3. Remote Control:
   • Supports remote control of process variables through RemoteControl, RemoteValue, and RemoteControlEnable.
4. Watchdog Logic:
   • Implements watchdog logic for process control loops as per TMC specifications.
5. Documentation Mapping:
   • Automatically maps files in the DATASTORAGEPATH/Documentation_<MachineModuleName>folder to OPC UA documentation properties.
6. Revision History:
   • Regular updates and improvements with detailed version history.

Supported Protocols and Standards

• OPC UA: Fully compliant with OPC UA standards.
• TMC2.0: Implements the Tobacco Machine Communication Information Model for OPC UA.
• Industrial Protocols: Supports Beckhoff ADS, Siemens S7-Ethernet, Hauni VHK, OPC XML-DA, OPC UA, Modbus TCP, and GD aHMI.

System Requirements

• Operating System: Linux (Docker Engine), Windows 10/11 (Docker Desktop), Windows 2022 Server (Docker Enterprise Edition).
• CPU Architecture: ARM32, ARM64, x86, x64.
• Hardware: Minimum 1GB RAM, 300MB storage, 1.5GHz CPU.

Licensing

• Licensed per machine module in scope.
• License Types:
  • Perpetual License: One-time purchase with optional annual support.
  • SaaS License: Annual subscription including support, upgrades, and updates.

MQTT Features

• Supported Protocols: MQTT v3.1, v5.0.
• Roles: Publisher and Subscriber.
• Topic Configuration: OPC UA BrowserPath-based schema, JSON files, and regular expression rule-based overrides.
• Buffering: Rolling 1-hour buffer for MQTT messages.

OPC UA Client Features

• OPC UA Roles: OPC UA Client.
• Specifications: OPC Unified Architecture V1.05.01, OPC 30060 Tobacco Machine Communication V2.00.1.
• Profiles: Standard UA Client 2017 Profile, TMC OPC UA Client Profile.
• Facets: State Machine Client, Durable Subscription, Data Access, Event Subscriber, Historical Access, Multi-Server Client Connection.

Host Requirements

• Operating Systems: Linux, Windows 10/11, Windows 2022 Server.
• CPU Architectures: ARM32, ARM64, x86, x64.
• Hardware Requirements: Minimum 1GB RAM, 300MB storage, 1.5GHz CPU.
• Logging: Built-in trace and audit logging, integrated with Docker.

CTA: Book a Demo

Aleph releases PSM, the first OPC UA - MQTT publisher based on OPC 10000-14 optimized for Data Fabric and Enterprise use.

PSM ensures compliance with OPC UA Part 14, enabling scalable, secure, and interoperable Pub/Sub communication for industrial IoT, cloud analytics, and real-time control systems.

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PSM is now available as a component of the Aleph FlexServer.

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CTA: Book a Demo

Several key features of PSM:

1. DataSet Management
   
   • Support PublishedDataSets for cyclic (e.g., sensor data) and acyclic (e.g., events) data.
   • DataSetMetaData to define field names, data types, semantics, and metadata (e.g., units, ranges).
2. Message Handling
   • DataSetMessages: Encode DataSets into payloads (key frames, delta frames or event frames)
   • Keep-Alive Messages: sent if no data is published within a configured interval.
3. Entities
   • Publishers: Generate and send NetworkMessages via MQTT
   • Subscribers: Receive, filter and decode NetworkMessages; map DataSet fields to target variables.
   • Security Key services (SKS): Manages key distribution and authentication.
   • Configuration Tool: Configure Pub/Sub components via OPC UA or offline files.
4. Transport Protocol Support
   • Broker-based Middleware: MQTT (v3.1.1 and v5) with support for topics, queues and QoS.
   • Transport Security: TLS for broker-based protocols;
5. QoS and Timing
   • PublishingInterval: Configurable interval for cyclic data.
   • Priority Labeling: Mapping to network QoS mechanism.
   • Timing Offsets: sampling, publishing, receive and processing offsets for synchronization.
6. Discovery Mechanisms
   • Multicast Discovery: UDP-based discovery probes/announcements for publishers.
   • Metadata Distribution: sending DataSetMetaData via NetworkMessages or OPC UA configuration methods.
7. Error handling and Diagnostics
   • MessageReceiveTimeout: Detect missing messages and trigger error states.
   • OverrideValueHandling: Configure fallback values (e.g. last usable vale, static override)
   • Diagnostics Counters: Track sent/received messages, errors and security events.
8. JSON-Specific Features
   • JSON NetworkMessage and DataSetMessage structure compliant with RFC 8254
     

Aleph releases AGS, the first TMC Compliant OPC UA Aggregation Server. As an aggregation server, AGS connects to multiple machines' OPC UA Servers and exposes the complete information set as one single aggregated server.

Customers use AGS to simplify and standardize their secure OPC UA connectivity, for example using AGS as a single secure entry point to a production line consisting of multiple machines each with its own OPC UA Server.

AGS is available as a Docker micro-service designed to run at the Edge that can be configured to aggregate only parts of the connected servers.

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AGS is now available as a component of the Aleph FlexServer.

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CTA: Book a Demo

The OPC Foundation releases for public use OPC 30060 OPC UA Companion Specification for Tobacco Machine Communication (TMC) Joint Working Group.

OPC 30060 is an OPC UA information model Aleph designed for the vertical adoption of OPC UA in the tobacco industry "for the common benefit of both OEM and cigarette manufacturers" as intended by the TMC Joint Working Group, whose members are British American Tobacco, Imperial Tobacco, Japan Tobacco International and Philip Morris International.

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OPC 30060 provides the infrastructure for interoperability of both legacy and new tobacco machines, modeling functionality into digital machines with the following key components:
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1. Material Flow

• Material Loading Points: machine components where materials are identified, validated against the production specification, loaded into the machines and the relevant dispensing/consumption is accounted for.
• Material Output Points: machine components where good product is released, identified, and the relevant inventory created.
• Material Rejection Points: machine components where out-of-specification material is released and accounted for. In conjunction with Defect Detection Sensors, they identify quality issues.
• Material Buffers: machine components where some material is temporarily stored in the machine, typically in the form of a small reservoir necessary to keep the flow uninterrupted.
• Machine Module Production: a machine's digital component managing information about the production order running at the machine, including starting and stopping production.

2. Quality

• Defect Detection Sensors: machine components or subsystems, including sensors and defect reasons, measuring quality parameters that may trigger the rejection of the product.
• Process Items: process measurements with their high-speed statistics generated at the machine.
• Machine Module Setup: a machine's digital component managing all the setup parameters for the product running at the machine.