Deliverable D100.3EPES ConceptEPES ProjectEco-Process Engineering System For Composition of Services to Optimize Product Life-cycleFoF-ICT-2011.7.3-285093Public Project ReportProject Facts:Duration:36 Months(September 2011 – August 2014)Programme:FP7 – ICTWebsite:http://www.epes-project.euThe EPES Project is co-funded by the European Commissionunder the FoF-ICT theme of the 7th Framework Programme (2007-2013)

EPESCopyrightCopyright 2012 by EPES ConsortiumAll rights reserved.No part of this project report may be reproduced, stored in a retrieval system, or transmitted inany form or by any means, electronic, mechanical, photocopying, scanning, or otherwise without prior written permission of the publisher. Except for quotation of short passages for the purpose of criticism and review.Trademarked names may appear in this report. Rather than use a trademark symbol with everyoccurrence of a trademarked name, we use the names only in an editorial fashion and to thebenefit of the trademark owner, with no intention of infringement of the trademark.The EPES project has no influence on the websites mentioned in this report and is not aware ofany illegal content on the pages referenced. Moreover, EPES dissociates itself explicitly fromall mentioned websites. This statement is valid for all links within this report.This publication was completed with the support of the European Commission under the 7thFramework Programme. The contents of this publication do not necessarily reflect the Commission's own position.EPES ConceptPage II

EPESAuthors and EPES Project PartnersAuthors and EPES Project PartnersFundacion Tecnalia Research &Innovationhttp://www.tecnalia.comSpainATBInstitut für angewandteSystemtechnik Bremen GmbHhttp://www.atb-bremen.deGermanySisteplant SLhttp://www.sisteplant.comSpainVTT Technical Research Centreof Finlandhttp://www.vtt.fiFinlandEsteco SpAhttp://www.esteco.comItalyGrupe Tamoin SAhttp://www.tamoin.comSpainnkt cables GmbHhttp://www.nktcables.comGermanyEADS Innovation Works UKhttp://www.eads.comEPES ConceptPage IIIUK

EPESSummarySummaryThis document represents the deliverable D100.3 EPES Concept and presents in detail the concept developed for the envisaged EPES solution, comprising the individual modules of the EPESsolution, the EPES reference architecture and the implementation plan.The EPES project’s objective is to support the Product Service System (PSS) by developing anovel eco process engineering system which will constitute a comprehensive platform, enablingdynamic composition of services adaptable to the different products and operating conditions.Thus, the EPES solution will support continuous improvement of products in operation along thelife cycle, applying the best up –to-date technologies for end of life disposal of the products andfor improving future product designs.To achieve these goals, the EPES project intends to develop: A set of ICT tools allowing easy configuration/adaptation of services storing and re-using knowledge in order to improve existing services and develop newonesA methodology and working handbookThe set of ICT tools, together with the methodology and working handbook, will enable themanufacturing companies to enter a continuous process of upgrading their products, along withtheir life cycle, within the frame of the virtual factory and PSS concept through a configurableand adaptable set of services.The key components of the EPES solution include: Virtual Collaborative Network (VCN): to allow the tracking of business optimizationopportunities through a networked infrastructure. It also provides collaborative web content and document content management capabilities. Service Generator (SG): to allow configuring services, deploying them and to provide acockpit/portal to access the EPES solution. Decision Making Module (DMM): to allow decision-makers to optimize and to analyzebusiness process through dedicated tools. Simulation Module (SM): execution of external simulations and provision of parametersfor calculation of key performance indicators (KPI).The EPES methodology will provide a comprehensive approach on how to use the EPESsolution. In order to enable applying the solution in a new situation, the methodology willinclude such aspects as business process model (mapping it and making it explicit), collectionof sustainability intelligence (SI) sources, classification and structuring of the SI information,etc. The overall way of working and expected functionalities of the SW modules are also to beincluded in the methodology.In order to ensure the industrial relevance of the EPES methodology, three application scenariosat the three industrial users of the consortium were studied and analysed for deriving a list ofrequirements. Furthermore, the RTD consortium partners have analysed state-of-the-art technologies, developments and available solutions based on their expertise (the results of this processhave been presented in deliverable D100.1 State-of-the-Art Analysis). Starting with the BC specific requirements and taking into account the technological state-of-the-art, a generic set of re-EPES ConceptPage V

EPESSummaryquirements has been extracted (presented in deliverable D100.2 Requirements Analysis). Theseare the requirements that the EPES solution must fulfil, and it is with these requirements in mindthat the EPES concept has been devised.This report includes a detailed description of the concept for all key components of the EPESsolution, architecture and methodology. The implementation plan, defining the scope of the Early and Full Prototypes, is also defined.EPES ConceptPage VI

EPESTable of ContentsTable of Contents1234Introduction . 111.1Document Purpose . 111.2Overview. 111.3Approach Applied . 121.4Document Structure . 12Generic Scenario . 142.1Business Case 1 . 142.2Business Case 2 . 162.3Business Case 3 . 172.4Common Scenario . 18EPES Reference Architecture . 233.1Rationale . 233.2Architecture Description . 23Methodology Concept . 264.1Introduction. 264.2EPES Methodology Objectives, Structure and Challenges . 264.2.1 Structure of the methodology .284.2.2 Organisational / Human issues in a Business Community .295Virtual Collaborative Network . 315.1Overview. 315.2Structure . 315.3Interfaces . 325.3.1 Inputs/Outputs.335.46Functionality . 34Service Generator. 366.1Overview. 366.2Structure . 366.3Interfaces . 376.3.1 Inputs/Outputs.386.4Functionality . 396.4.1 SG Configuration Services .406.4.2 SG Cloud Services .406.4.3 Cockpit/Aggregator .40EPES ConceptPage VII

EPESTable of Contents6.4.4 Security .406.4.5 Infrastructure.406.4.6 Context Model .406.4.7 Context Extractor .417Decision Making Module . 427.1Overview. 427.2Structure . 427.3Interfaces . 447.3.1 Inputs/Outputs.447.48Functionality . 46Simulation Module . 488.1Overview. 488.2Functionality . 498.3Structure . 498.3.1 Use of existing platforms .508.4Interfaces . 518.4.1 Inputs/Outputs.529Implementation framework and plan . 549.1Software Engineering Approach . 549.1.1 Service oriented engineering .559.2Implementation schedule . 569.2.1 Early prototype content .579.2.2 Full prototype content .5710Conclusions . 58EPES ConceptPage VIII

EPESAbbreviationsAbbreviationsAPIApplication Programming InterfaceOSOAOpen SOABCBusiness CasePAMPassword Authentication ModuleBIBusiness IntelligencePSSProduct Service SystemBPELBusiness Process ExecutionLanguageR&DResearch and DevelopmentRESTBPMBusiness Process ManagementREpresentational State TransferBPMNBusiness Process Model andNotationRESTfulConforming to REST constraintsBusiness Process ManagementSystemRPCRemote Procedure CallsRTDResearch and TechnologicalDevelopmentRTERound-trip EngineeringS&TScientific and TechnologicalSCAService Component ArchitectureSCADASupervisory Control and DataAcquisitionBPMSCMMSComputerized MaintenanceManagement SystemsCMSDCore Manufacturing SimulationData (Standard)CRUDCreate-Read-Update-DeleteDESDiscrete Event SimulationDMDecision MakingDMMDecision Making ModuleSDOService Data ObjectsDoEDesign of ExperimentsSGService GeneratorDTSDistributed Temperature SensingSGMService Generator ModuleSISustainability Intelligencee.g.exempli gratia for exampleSMSimulation ModuleEPESEco-Process Engineering SystemSMESmall and Medium Sized EnterpriseERPEnterprise Resource PlanningSOAService Oriented ceteraSOAPSimple Object Access ProtocolETLExtract, Transform and LoadSWSoftwareEUEuropean UnionTBLTriple Bottom LineGISGeographic Information SystemTOCTheory Of ConstraintsGUIGraphical User InterfaceUMLUnified Modelling est that is to sayVBEVirtual Breeding EnvironmentICTInformation and CommunicationTechnologyVCNVirtual Collaborative NetworksIPRIntellectual Property RightsVFDBVirtual Factory DatabaseITInformation TechnologyVFKDBVirtual Factory Knowledge DatabaseKPIKey Performance IndicatorWPWorkpackageLCLife CycleWSWeb ServicesLCILife Cycle InventoryWSDLLCMLife Cycle ManagementWeb Services Description LanguageOLAPOnline Analytical ProcessingXMLeXtensible Markup LanguageEPES ConceptPage IX

EPES11.11 IntroductionIntroductionDocument PurposeThis document summarizes the conceptual development of the EPES project. It presents the deliverable D100.3 EPES Concept, which is the result of Task T130 Concept Definition from WorkPackage WP100, Requirement Analysis and Concept.The EPES concept provides the overall concept for methodology, architecture, software components, service infrastructure, and implementation framework. The concept has been developedbased on the results of the tasks T110 (State-of-the-art Analysis) and T120 (Requirements Collection and Analysis).1.2OverviewThe strategic objective of the EPES project is to develop a novel eco process engineering system,which will constitute a comprehensive platform enabling a dynamic composition of servicesadaptable to the different products and operating conditions, supporting the Product Service System.This novel service oriented framework will allow industries to evaluate the performance of engineered products considering their whole lifecycle rather than only early stages such as designand manufacturing (see Figure 1-1 below). The capabilities resulting from the research will enable the capitalisation on trustable global and local sustainability intelligence. Product engineeringteams can exploit this intelligence to adapt design, operation and disposal strategies throughmanaged “eco-constraints” relevant to their market contexts.Figure 1-1: Basic EPES ConceptThis concept document defines the relation to the state of the art at the beginning where the identified gaps and EPES contributions in relevant R&D areas are mentioned. EPES conceptual development is guided by a generic scenario obtained from analysing detailed requirements ofthree industrial application scenarios. This ensures industry relevant development of EPESmethodology and services/modules as the requirements are directly derived from three differentuse cases and analysing the current state of the art. Based on these requirements, overall EPESreference architecture, features and functionality required for EPES solutions are derived. In theEPES ConceptPage 11

EPES1 Introductionfinal part of this document, required implementation framework, plans for implementation andconclusions are drawn.1.3Approach AppliedThe EPES concept presented here is the result of a process already partly presented in the previous deliverable D100.2 Requirements Analysis and illustrated in Figure 1-2 below.ConceptGeneric RequirementsBCInstancesRequirementsGeneric EPES ScenariosOwn Solutions& SotAExpertise& SotAConsortiumICT vationsFigure 1-2: Approach applied in the requirements analysisShortly, the steps of that process were:1.Detailed analyses of the application cases by the three industrial partners.2. Creation of the textual descriptions of the application cases and extraction of needs andrequirements.3. Collection of the information/insight into the market available solutions and into thestate-of-the-art of corresponding application.4. On top of that the RTD performers have created an in-depth analysis of the state-of-theart R&D activities in the relevant areas, what was used, enriched by the expertise (ofRTD performers), for creation of a generic set of requirements and generic applicationscenarios.5. All participants in the above described activities (see Figure 1-2) have also providedtechnical visions and innovation ideas to complete the generic requirements. The attemptwas done to introduce the long-term visions for the future improvements of the solutions.6. The generic scenarios presented in section 2 are to be observed also as a kind of contribution to the generic requirements upon the EPES components functionalities.7. Based on the defined requirements the key EPES components are specified in detail.1.4Document StructureThe document is structured as follows:Section 1 – presents the purpose of the document, an overview of the project and the report’sposition in the project, as well as approach applied.Section 2 – provides the generic scenarios as explained above.EPES ConceptPage 12

EPES1 IntroductionSection 3 – describes the EPES reference architecture.Section 4 – provides detailed description of the Methodology Concept.Section 5 – provides detailed description of the Virtual Collaborative Network Module.Section 6 – provides detailed description of the Service Generator Module.Section 7 – provides detailed description of the Decision Making Module.Section 8 – provides detailed description of the Simulation Module.Section 9 – includes description of the implementation framework and implementation plan.Section 10 – provides conclusions indicating future work.EPES ConceptPage 13

EPES2 Generic Scenario2 Generic ScenarioThis section presents the process used to identify the generic EPES solution architecture whichmeets the requirements derived from industrial business cases analysis. In the first phase, thecase scenarios are illustrated here from the technical viewpoint for potential EPES solution integration. In the second phase, the potential EPES solution integrations envisaged for each BC areabstracted into a Generic Scenario which will serve as the basis for the EPES solution specification.The EPES project covers three industrial application scenarios (business cases): Business Case 1: Engineering maintenance services for optimizing maintenance and increasing availability of wind turbines Business Case 2: Power grid control systems for improved identification of maintenanceneeds and improved monitoring of grid load and safety limits Business Case 3: Support for optimized design and manufacturing of aircraft wingsTable 2-1 presents an overview of the envisaged usage of the EPES ICT components within thethree EPES Business Cases. The following subsections first describe each of the three businesscases1 and afterwards present the generic scenario derived from these business cases.Table 2-1: Envisaged usage of the EPES ICT componentsEPES ICT ComponentBC1BC2BC3Virtual Collaborative Networks /VBE Virtual Factory Service Generator Simulation Module Decision Making Module 2.1Business Case 1ENGINEERINGMAINTENANCE SERVICES FOR OPTIMIZING MAINTENANCE AND INCREASINGAVAILABILITY OF WIND TURBINESThe overall objective of this Business Case is to optimize TAMOIN-TER maintenance procedures carried out at their client’s wind farms so as to achieve maximum wind turbines availability at minimum maintenance costs focusing on a holistic sustainable approach, through the KPImonitoring and the adoption of simulation and optimization services provided by EPES system.The first key objective will focus on a system for capturing environmental eco-constraints derived from local regulations, regional regulations and sector recommendations, aiming at theidentification and development of eco indicators involving social and environmental measures.On the other hand, the system will also allow the extraction, transformation and loading of human, material and technical data into a data warehouse in order to support the definition andelaboration of traditional key performance indicators involving profit measures. The monitoring1Detailed overview and objectives of the three business cases is presented in deliverable D100.2EPES ConceptPage 14

EPES2 Generic Scenarioand tracking of these indicators (before and after the implementation of business process optimizations) will support the decision making process to achieve an optimal management of TERmaintenance process.The second key objective is to improve the maintenance scheduling capabilities of TER by theimplementation of a scheduling system based on mathematical models aimed to optimize thetotal energy produced by the wind turbines while minimizing the maintenance costs. These models will be enhanced with service oriented capabilities and offered as services through EPES solution in order to provide collaborative, traceable and trustable decision support to TER. Thisscheduling facility will be accessed through a collaborative workflow system, which will allowmodelling and executing TER maintenance process, the connection of this process to existing ITlegacy systems, the assignment of the different process activities to different users and the monitoring of the whole process through the KPIs elaborated as result of the first key objective.The main components of the BC1 scenario are: PRISMA Computerized Maintenance Management System, which acts as an ERP and asa maintenance planning and tracking tool Scheduling models (based on linear programming or genetic algorithms), which will provide TER with optimization tools to improve the maintenance process Unstructured technical data coming from the wind turbines SCADA systemsFigure 2-1 below illustrates how the EPES solution can be integrated with the BC1.Figure 2-1: An architectural viewpoint of the EPES solution integration with BC1EPES ConceptPage 15

EPES2.22 Generic ScenarioBusiness Case 2POWER GRID CONTROL SYSTEMS FOR IMPROVED IDENTIFICATION OF MAINTENANCE NEEDSAND IMPROVED MONITORING OF GRID LOAD AND SAFETY LIMITSThe main objective of this business case is to provide new business models to offer their customers maintenance services (e.g. in respect to detailed analysis detection of faults, etc.), as well asconfigurable cable monitoring services, easily adaptable to customer specific requirements, enabling an optimal usage of available capacity and secure operation of high and extra-high voltagecables.Identified key objectives of the EPES solution’s integration for this business case2 comprise: Improved identification of maintenance needs Improved monitoring of the grid load Provide adjusted parameter sets to human operator for final decisionFigure 2-2 below presents the architectural view of integrating the EPES solution with the BC2:Figure 2-2: An architectural viewpoint of the EPES solution integration with BC2The main components of the BC2 scenario are:2 AdapPro: allows computing of load predictions for a chosen date and time in the future VALCAP: allows monitoring the power grid’s parameters Distributed Temperature Sensing (DTS): allows sensing the temperature of power cablesDetailed overview and objectives of business case 2 is listed in section 2.2, page 20 of deliverable D100.2EPES ConceptPage 16

EPES 2 Generic ScenarioSCADA: control and data acquisition system used to interface with the power cablesThe data from VALCAP and DTS is used in conjunction with the SM and DMM to compute theparameters needed for customizing new services.2.3Business Case 3SUPPORT FOR OPTIMIZED DESIGN AND MANUFACTURING OF AIRCRAFT WINGSMain objectives of the EPES system in this BC are to bring new supporting services for assessment of productivity and sustainability KPIs on wing design (defined at the conceptual stage).By using such services the EPES system enables to validate production scenarios on early stagesconsidering dynamic conditions. Furthermore, improved decision making for an optimum manufacturing facility will be supported.Figure 2-3: An architectural viewpoint of the EPES solution integration with BC3The end users of the EPES system will be “design for manufacturing” engineers, within the enterprise, contributing in the assessment of design concepts. The EPES system will support themto make informed decisions on the performance of design concepts from the manufacturing perspective. EPES systems brings an opportunity to integrate the assessment of traditional manufacturing Key Performance Indicators (KPIs) such as time and production rate with those related tothe sustainability of the production processes. The essential questions answered through this assessment are: Productivity KPIs: What production rate can be achieved for a design using a given set ofprocesses and resources? Sustainability KPIs: What are the energy consumption, the emissions and the hazardousmaterial waste resulting from the manufacturing for a design using a given set of processes and resources?The main components of the BC3 scenario are:EPES ConceptPage 17

EPES2 Generic Scenario Enterprise existing legacy systems Discrete event simulation (DES) software and Excel interface to run the simulation models Life Cycle Inventory data2.4Common ScenarioThe potential integration views of the three BC scenarios with the EPES solution have been analysed in order to extract a generic scenario. Figure 2-4 below presents a generic view of the envisaged EPES solution, highlighting on the one hand the generic EPES solution integration, andon the other hand a generic view of BC-specific infrastructure.Figure 2-4: EPES Architecture: generic view of business casesTable 2-2 lists the identified main specific technical aspects of the three cases which will be addressed by the generic EPES solution.Table 2-2: BC-specific technical aspects addressed by the EPES solutionBusiness Main Area of InterestCaseBC1EPES ConceptTechnical issues to be addressed withEPESEngineering maintenance ser- Monitor parameters of wind turbines to detectPage 18

EPES2 Generic Scenariovices for optimizing mainte- (preventive) maintenance needsnance and increasing availability of wind turbinesBC2Power grid control systems for Monitoring of cable temperaturesimproved identification ofMonitoring of grid loadmaintenance needs and improved monitoring of grid loadand safety limitsBC3Support for optimized design Use simulations to estimate production rate, enand manufacturing of aircraft ergy consumption, emissions, hazardous materialwingswasteEPES ConceptPage 19

EPES2 Generic ScenarioFigure 2-5 below presents a UML use case diagram of the main features of the EPES modules.There are three kinds of users of the system. The developer user is responsible for the integrationof external simulation tools by using the interactive features of the Simulation module. The expert user is responsible for configuring simulation services in the Service Generator module, bywrapping the services provided by the Simulation module. The expert user uses the interactivefeatures of the Decision Making module to run simulations and process the results.EPES ConceptPage 20

EPES2 Generic ScenarioFigure 2-5: A UML use case diagram of the main EPES module featuresEPES ConceptPage 21

EPES2 Generic ScenarioThere are several dependencies between the use-cases of the modules. The dashed arrows in thefigure represent flows of persistent data that must be available through the common Content Repository. The “uses” arrows represent inclusion of use-cases and “extends” represent extension.A “uses” dependency between the modules will be implemented as a call to a service interface,while the dashed arrows represent access to common persistent data in the content repository.EPES ConceptPage 22

EPES3 EPES Reference Architecture3 EPES Reference Architecture3.1RationaleA Reference Architecture captures the essence of the architecture of a collection of systems. Thepurpose of a Reference Archite

This document represents the deliverable D100.3 EPES Concept and presents in detail the con-cept developed for the envisaged EPES solution, comprising the individual modules of the EPES solution, the EPES reference architecture and the implementation plan. The EPES project's objective is to support the Product Service System (PSS) by developing a