What is SCADA SCADA is an acronym that stands for Supervisory Control and Data Acquisition.

SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data. There are many parts of a working SCADA system. A SCADA system usually includes signal hardware (input and output), controllers, networks, user interface (HMI), communications equipment and software. All together, the term SCADA refers to the entire central system. The central system usually monitors data from various sensors that are either in close proximity or off site. For the most part, the brains of a SCADA system are performed by the Remote Terminal Units (RTU). The Remote Terminal Units consists of a programmable logic converter. The RTU are usually set to specific requirements, however, most RTU allow human intervention, for instance, in a factory setting, the RTU might control the setting of a conveyer belt, and the speed can be changed or overridden at any time by human intervention. In addition, any changes or errors are usually automatically logged for and/or displayed. Most often, a SCADA system will monitor and make slight changes to function optimally; SCADA systems are considered closed loop systems and run with relatively little human intervention. One of key processes of SCADA is the ability to monitor an entire system in real time. This is facilitated by data acquisitions including meter reading, checking statuses of sensors, etc that are communicated at regular intervals depending on the system. Besides the data being used by the RTU, it is also displayed to a human that is able to interface with the system to override settings or make changes when necessary. SCADA can be seen as a system with many data elements called points. Usually each point is a monitor or sensor. Usually points can be either hard or soft. A hard data point can be an actual monitor; a soft point can be seen as an application or software calculation. Data elements from hard and soft points are usually always recorded and logged to create a time stamp or history SCADA can come in open and non proprietary protocols. Smaller systems are extremely affordable and can either be purchased as a complete system or can be mixed and matched with specific components. Large systems can also be created with off the shelf components. SCADA system software can also be easily configured for almost any application, removing the need for custom made or intensive software development.

Modular production system program process flow (software engineer)

Sorting and handling Sensor (Checking for full line storage)

(Switch) No
Checking for full rack

Yes

Process continues to pack on the sorting and handling rack

Send signal to ASRS to keep carrier

Sensor No
Check for need product

yes

No

ASRS check for product on the carrier

Yes

Send Signal to ASRS and arm will collect from storage and place on carrier

ASRS to send output to the arm to collect product on carrier

Release Full carrier

No

Check for full ASRS rack

Arm place product from bottom right to left and up

Process stops

Release empty carrier

Task 4 1. Comparison of modular Production system and Open system interconnection (OSI) reference model Modular Production System MPS seeks to provide a radical new manufacturing business framework suitable for the agile manufacturing period. The module standards are based upon a unified reduced set of primitive production elements which are at a level of modularity lower than previously. The module categories comprise of just four classes, namely process machine primitives, motion units, modular featuring and configurable control systems). The belief is that appropriate selection of modules from these categories will enable a diverse range of efficient, automated and integrated production systems to be built.

Since the Industrial Revolution manufacturing methods have been characterized by process centered work organisation in which material and components are transferred from machine to machine. However, manufacturing requirements have changed extremely in the last few decades and today the emphasis is on greater responsiveness, cost effectiveness, improved production quality and shorter product life-cycles. As a result, it is increasingly becoming evident that traditional process centered production methods and work structures are proving inappropriate to meet the new demands. Put simply, there is now pressure to restructure manufacturing along new lines. To meet this new period of responsive manufacturing the Modular Production Systems manufacturing concept seeks to establish a radical new manufacturing paradigm based upon standardising both the production system elements and the methods of production system design. Combined with powerful design tools the belief is that entire fully integrated component production and assembly systems will be able to be rapidly configured for producing a wide range of low to medium technology consumer goods. MPS manufacturing will result in a major change in manufacturing business operation. In particular, the construction of an MPS will probably best be undertaken by specialist system builders who are solely responsible for the leasing of module hardware and the building of such production systems. 'Manufacturers' will then be more concerned with product design, marketing and sales. Ultimately this could give rise to geographically distributed 'generic' factories which are leased to 'manufacturers' who seek their production capabilities.

Benefits resulting from MPS

Building on these new principles of integrated manufacturing and systematic production system design the following section summaries how, through adoption of the MPS approach, the new manufacturing objectives identified in section 1.0, would be satisfied. Shorten the design to market lead time.

Designing products explicitly for ease of manufacture and assembly is recognised as one of the principal means of reducing time to market. Because the MPS method enables the development of systematic MPS design procedures (though computationally complex in nature) automation of the design process is feasible. This automation, combined with simplified production system construction resulting from standardised modularity, will help to significantly shorten production lead times by enabling a significant reduction in the time needed to design and configure a new production system. Ensure all goods are produced with high and consistent quality.

MPS exploits the systems principle that combining units of known performance and reliability results in systems of equally predictable performance and reliability. As a result, provided appropriate standards are chosen and the MPS design algorithms are correct, then the MPS methods will ensure products are produced with consistent and known quality. Forecast production costs and lead-times

MPS supports virtual manufacturing by enabling the modeling of all aspects of production. As a consequence, since MPS design is computer oriented, the belief is that production system costs and construction times can be predicted prior to investment in hardware. Alter production capacity without significant costs or production lead-times.

By having precise computer models of MPS hardware and systematic procedures for MPS design the belief is that it will be feasible to readily alter the elements and structure of a MPS to match the production rates throughout lifecycle market demands. As a result the production system can be optimally tuned to maximise utilisation of the modular machinery. Frequently introduce new products to retain or gain market share.

Because MPS design is automated and the hardware is modular it becomes feasible to rapidly configure and re-configure production systems without

significant costs and time. Moreover, the redundant modular hardware can be reused a later date for another MPS.

Open system interconnection (OSI) reference model The Open System Interconnection Reference Model (OSI Reference Model or OSI Model) is an abstract description for layered communications and computer network protocol design. It was developed as part of the Open Systems Interconnection (OSI) initiative. In its most basic form, it divides network architecture into seven layers which, from top to bottom, are the Application, Presentation, Session, Transport, Network, Data-Link, and Physical Layers. It is therefore often referred to as the OSI Seven Layer Model. A layer is a collection of conceptually similar functions that provide services to the layer above it and receives service from the layer below it. On each layer an instance provides services to the instances at the layer above and requests service from the layer below. For example, a layer that provides error-free communications across a network provides the path needed by applications above it, while it calls the next lower layer to send and receive packets that make up the contents of the path. Conceptually two instances at one layer are connected by a horizontal protocol connection on that layer.

Figure 1: Example of ISO model with layers 3 to 5.

Description of OSI layers OSI Model Data unit Layer 7. Application Host Data layer s 6. Presentation 5. Session Function Network process to application Data representation and encryption Interhost communication End-to-end connections and reliability Path determination and logical addressing Physical addressing Media, signal and binary transmission

Segment 4. Transport Packet Media layer Frame s Bit 3. Network 2. Data Link 1. Physical

Layer 1: Physical Layer The Physical Layer defines the electrical and physical specifications for devices. In particular, it defines the relationship between a device and a physical medium. This includes the layout of pins, voltages, cable specifications, Hubs, repeaters, network adapters, Host Bus Adapters (HBAs used in Storage Area Networks) and more. To understand the function of the Physical Layer in contrast to the functions of the Data Link Layer, think of the Physical Layer as concerned primarily with the interaction of a single device with a medium, where the Data Link Layer is concerned more with the interactions of multiple devices with a shared medium. The Physical Layer will tell one device how to transmit to the medium, and another device how to receive from it (in most cases it does not tell the device how to connect to the medium). The major functions and services performed by the Physical Layer are:

Establishment and termination of a connection to a communications medium.

Participation in the process whereby the communication resources are effectively shared among multiple users. For example, contention resolution and flow control. Modulation or conversion between the representation of digital data in user equipment and the corresponding signals transmitted over a communications channel. These are signals operating over the physical cabling (such as copper and optical fiber) or over a radio link.

Parallel SCSI buses operate in this layer, although it must be remembered that the logical SCSI protocol is a Transport Layer protocol that runs over this bus. Various Physical Layer Ethernet standards are also in this layer; Ethernet incorporates both this layer and the Data Link Layer. The same applies to other local-area networks, such as Token ring and IEEE 802.11, as well as personal area networks such as Bluetooth and IEEE 802.15.4. Layer 2: Data Link Layer The Data Link Layer provides the functional and procedural means to transfer data between network entities and to detect and possibly correct errors that may occur in the Physical Layer. Originally, this layer was intended for point-to-point and point-to-multipoint media, characteristic of wide area media in the telephone system. Local area network architecture, which included broadcast-capable multi-access media, was developed independently of the ISO work, in IEEE Project 802. IEEE work assumed sub layering and management functions not required for WAN use. In modern practice, only error detection, not flow control using sliding window, is present in modern data link protocols such as Point-toPoint Protocol (PPP), and, on local area networks, the IEEE 802.2 LLC layer is not used for most protocols on Ethernet, and, on other local area networks, its flow control and acknowledgment mechanisms are rarely used. Both WAN and LAN services arrange bits, from the Physical Layer, into logical sequences called frames. Not all Physical Layer bits necessarily go into frames, as some of these bits are purely intended for Physical Layer functions. For example, every fifth bit of the FDDI bit stream is not used by the Layer. Layer 3: Network Layer

The Network Layer provides the functional and procedural means of transferring variable length data sequences from a source to a destination via one or more networks, while maintaining the quality of service requested by the Transport Layer. The Network Layer performs network routing functions, and might also perform fragmentation and reassembly, and report delivery errors. Routers operate at this layer sending data throughout the extended network and making the Internet possible. This is a logical addressing scheme values are chosen by the network engineer. The addressing scheme is hierarchical.

Layer 4: Transport Layer The Transport Layer provides transparent transfer of data between end users, providing reliable data transfer services to the upper layers. The Transport Layer controls the reliability of a given link through flow control, segmentation/desegmentation, and error control. Some protocols are state and connection oriented. This means that the Transport Layer 5: Session Layer The Session Layer controls the dialogues (connections) between computers. It establishes, manages and terminates the connections between the local and remote application. It provides for full-duplex, half-duplex, or simplex operation, and establishes check pointing, adjournment, termination, and restart procedures. The OSI model made this layer responsible for graceful close of sessions, which is a property of the Transmission Control Protocol, and also for session check pointing and recovery, which is not usually used in the Internet Protocol Suite. The Session Layer is commonly implemented explicitly in application environments that use remote procedure calls. Layer 6: Presentation Layer The Presentation Layer establishes a context between Application Layer entities, in which the higher-layer entities can use different syntax and semantics, as long as the Presentation Service understands both and the mapping between them. The presentation service data units are then encapsulated into Session Protocol Data Units, and moved down the stack. This layer provides independence from differences in data representation (e.g., encryption) by translating from application to network format, and vice versa. The presentation layer works to transform data into the form that the application layer can accept. This layer formats and encrypts data to be sent across a network, providing freedom from compatibility problems. It is sometimes called the syntax layer. Layer 7: Application Layer The application layer is the OSI layer closest to the end user, which means that both the OSI application layer and the user interact directly with the software application. This layer interacts with software applications that implement a communicating component. Such application programs fall outside the scope of the OSI model. Application layer functions typically include identifying communication partners, determining resource availability, and synchronizing communication. When identifying communication partners, the application layer determines the identity and availability of communication partners for an application with data to transmit. When determining resource availability, the

application layer must decide whether sufficient network resources for the requested communication exist. In synchronizing communication, all communication between applications requires cooperation that is managed by the application layer.

2. Manufacturing protocols and identify which protocols for modular production system