Technical Information

TI 34P02A01-02E

Introduction to STARDOM

TI 34P02A01-02E 1st Edition Feb. 2002

To To Win Win in in Increasingly Increasingly Fierce Fierce Global Global Race Race
Business Business Condition Condition of of Manufacturing Manufacturing Industry Industry
Shorter Shorter lead lead time time from from order to shipment order to shipment Changing Changing market market preferences preferences (diversifying (diversifying needs) needs) To To survive survive the the global global competition competition Demand Demand for for superior superior quality quality at at lower lower price price

to to support support the the manufacturing manufacturing industry industry in in the the 21st 21st century. century.

Implement Implement e-RM e-RM (electronic (electronic Realtime Realtime Manufacturing) Manufacturing)
It It is is essential essential to to promote promote the the new new manufacturing manufacturing concept, concept, e-RM, e-RM, which which will will boost manufacturing efficiency, swiftly adapt to changes in market boost manufacturing efficiency, swiftly adapt to changes in market demand, demand, and and enable enable products products to to be be manufactured manufactured profitably. profitably.

Key Key requirements requirements for for e-RM e-RM

Information Information integration: integration: Responding Responding to to market market information information in in real real time time Agility: Agility: Agilely Agilely adopting adopting to to changes changes for for efficient efficient manufacturing manufacturing Reliability: Reliability: Assuring Assuring quality, quality, cost, cost, and and delivery delivery

Background to Development of STARDOM

Business Condition of Manufacturing Industry
As e-commerce and supply chain management have progressed, thus speeding up order handling and delivery in todays manufacturing industry, production systems must also be capable of responding to changes in real time. But the industry is also facing rapidly changing market preferences as well as demands for better quality at lower cost.

A New System Concept e-RM

To meet these requirements and survive the intensifying global competition, production systems need to employ a new concept. As a solution for the manufacturing industry, Yokogawa proposes e-RM (electronic Realtime Manufacturing), a new manufacturing system concept that radically boosts manufacturing efficiency, quickly adapts to shifts in market demand, and ensures manufacturing of required products at profitable cost.

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TI 34P02A01-02E

Feb.28,2002-00

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Network Network Based Based Control Control System System STARDOM STARDOM

A A production production system system that that meets meets the the 3 3 key key needs needs of of e-RM e-RM
Networks Networks integrate integrate the the control control domain domain and link up with the business and link up with the business framework framework systems systems to to respond respond to to market market information information in in real real time. time.

Information Information integration integration

To To Win Win in in Increasingly Increasingly Fierce Fierce Global Global Race Race
Agility Agility Reliability Reliability
Adapts Adapts to to the the market, market, swiftly swiftly varies production varies production and and brands brands to to be be manufactured. manufactured.

Assures Assures quality, quality, cost cost and and delivery. delivery.

Network Based Control System STARDOM

STARDOM meets the three key requirements for e-RM.

Information Integration
With open and highly independent components linked to each other via a network, STARDOM enables integration of information such as the control domain, linking up with business framework systems, real-time manufacturing and efficient operation.

Agility
STARDOM proposes system configurations designed for distributed installation to distribute functions, and promotes the breaking down of application programs into software parts and reuse of them. When production and brands then need to be changed to accommodate changes in market preferences, manufacturing changes can be made quickly and easily.

Reliability
STARDOM has a highly reliable architecture that risk hedge by distributed installation, dualredundant enabled controllers, and more for ensuring steady operation, production quality, low manufacturing cost, and timely delivery.

All Rights Reserved. Copyright 2002, Yokogawa Electric Corporation

TI 34P02A01-02E

Feb.28,2002-00

Components Components of of STARDOM STARDOM

Open, Open, highly highly independent independent components components based based on on network network technologies technologies Users Users can can select select the the optimum optimum
Web-based Web-based HMI/SCADA HMI/SCADA Software Software

Network Network
Application Application Portfolios Portfolios (libraries of (libraries of software software parts parts containing containing application application expertise) expertise) All-in-one, Autonomous All-in-one, Autonomous Controller Controller

Modulus, Modulus, Autonomous Autonomous Controller Controller

Components of STARDOM
To meet the three requirements for production systems, STARDOM offers a lineup of network technology-based, open, highly independent components.

VDS Versatile Data Server Software

VDS Versatile Data Server Software, which is Web-based HMI/data server software, adds cutting-edge network technologies to the conventional HMI/SCADA functionality such as data acquisition from various I/O devices, data saving, and process operation via a high-definition graphical user interface. VDS makes operation and maintenance that much simpler.

FCN and FCJ Autonomous Controllers

In addition to conventional combined functions such as regulatory control and sequence control, STARDOMs autonomous controllers have a highly independent architecture for linking up distributed controllers and devices in the control domain and autonomously transmitting information without relying on HMI software. The many benefits include the design for distributed installation to distribute functions and risk hedge, and promotion for registration of reusable software parts, thus making engineering more efficient, from purchase and operation to expansion and modification. The autonomous controllers are available in two types: the FCJ (field control junction) all-in-one controller and FCN (field control node) controller that can have a dual-redundant configuration.

APPF Application Portfolios

Yokogawa has put its decades of expertise in configuring control functions into libraries of software parts available as Application Portfolios. By using control logic parts from a portfolio that meet the specification requirements, advanced functions can be implemented more quickly and reliably.

All Rights Reserved. Copyright 2002, Yokogawa Electric Corporation

TI 34P02A01-02E

Feb.28,2002-00

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Information Information Integration: Integration:

Increased Increased Manufacturing Manufacturing Efficiency Efficiency by by Inter-system Inter-system Link Link
Link with Link withbusiness businessframework frameworksystems systems Link Linkwith withbusiness businessframework frameworksystems systems
MES, MES,ERP ERP Report Report management management

for for a a network-based network-based control control system system (NCS) (NCS)

Remote operation Remote operation Remote Remoteoperation operation

General GeneralWeb Webbrowser browser

Reception of site Reception of site Reception of site Reception of site information by e-mail information by e-mail information by information bye-mail e-mail
Portable Portableterminals terminals

Network Network
Facility FacilityC C Facility FacilityB B System link System link System Systemlink link Message transmission Message transmission Message transmission Message transmission by e-mail by e-mail by bye-mail e-mail Facility Facility A A Controller link Controller link Controller Controllerlink link

Using Using networks networks to to integrate integrate information information

Increased Increased manufacturing manufacturing efficiency efficiency (by (by integration integration of of control control domain) domain) Quicker Quicker response response to to market market information information (by (by link link with with business business framework framework systems) systems) Improved Improved operation operation efficiency efficiency (by (by effective effective use use of of remote remote operation operation and and portable portable terminals) terminals)
Temperature Temperature controllers controllersand and power powermonitors monitors

Other Other vendors vendors PLCs PLCs Field Fieldnetwork network Display Displayunits units

Device link Device Device link Devicelink link

Increased Manufacturing Efficiency by System Link

The Internet is no longer for only exchanging information, but is becoming the basis for business transactions and distribution. Various field devices now come with network connectivity as standard, allowing comprehensive integrated management of not merely conventional control but also management information. By combining such networks with production systems, the individual components of STARDOM enable a network-based control system (NCS) to be built that integrates the control domain and links up with the business framework systems such as MES, ERP to boost manufacturing efficiency.

Integration of Control Domain Horizontal Integration

Seamless data linkage between controllers and integration of various I/O devices for different purposeswhether for factory or process automation equipment, STARDOM can link up production lines and manufacturing processes from raw material loading and product unloading and integrate the information of lines and processes to increase manufacturing efficiency.

Linkage with Business Framework Systems Vertical Integration

Linkage with business framework systems that encompass MES, ERP and quality control creates a production system that responds to market information in real time.

Remote Operation
With Web-based operation, a PC connected to the Internet can be used to access, monitor and operate the site via a Web browser anytime, anywhere. The controllers in the field can autonomously transmit messages to portable terminals, thus improving operation efficiency.

All Rights Reserved. Copyright 2002, Yokogawa Electric Corporation

TI 34P02A01-02E

Feb.28,2002-00

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Agility: Agility:

Quick Quick Response Response to to Market Market Changes Changes

Flexible Flexible configuration configuration for for each each application application
Controllers Controllers designed designed for for distributed distributed installation installation to to distribute functions distribute functions Wealth Wealth of of software software for for any any scale scale of of system system

Libraries Libraries of of application application parts parts for for efficient efficient engineering engineering
IEC61131-3-compliant IEC61131-3-compliant languages languages for for programming controller programming controller applications applications
Promotes Promotesregistration registrationand and reuse reuseof ofparts partsof ofprograms. programs. Support Supportfor forcreation creationof of parts parts Hierarchically Hierarchically structured structuredprograms programs Adheres Adheresto to International International standard standardfor for engineering engineering methods. methods.

Expertise Expertise in in applications applications available available as as software parts software parts
Registers Registers complex complex functions functionsas asa a reusable reusablepart. part.

Can Canchoose choosefrom fromfive fivelanguages languages depending dependingon onthe theapplication: application: Function FunctionBlock BlockDiagram Diagram(FBD) (FBD)

Ladder LadderDiagram Diagram(LD) (LD) Sequential SequentialFunction FunctionChart Chart(SFC) (SFC) Structured StructuredText Text(ST) (ST) Instruction InstructionList List(IL) (IL)

Application ApplicationPortfolios Portfolios

Libraries Librariesof ofsoftware softwareparts partsembodying embodying Yokogawas Yokogawasdecades decadesof ofexpertise expertise Effortless Effortlessimplementation implementation of of sophisticated sophisticatedfunctions functions Ensured Ensuredstability stability

Agile Response to Changes in Market

STARDOM proposes system configurations designed for distributed installation to distribute functions and promotes the breaking down of application programs into software parts and reuse of them. Production and brand changes can then be made quickly to suit changes in market preferences.

Flexible Configuration for Each Application

The FCN and FCJ autonomous controllers are carefully designed for distributed installation, featuring complete inter-controller communication functionality, compact hardware for easy installation on site, scalable software architecture, and more. Functional distribution means not only more flexible configuration when employing a system, but also facilitates expansion and modification of facilities.

Libraries of Application Parts for Efficient Engineering

IEC61131-3-compliant languages for programming controller applications The languages for programming control logic to be run on FCNs and FCJs are compliant with the IEC61131-3 international standard. In addition to engineering using internationally standard methods, the hierarchically structured programs and the feature allowing users to break down developed programs into parts by a set of functions promote the reuse of programs and greatly simplify expansion and modification. Expertise in applications available as software parts Application Portfolios (APPF) are libraries of parts embodying Yokogawas expertise. Portfolio parts can be used to build sophisticated, reliable applications running on FCNs and FCJs. These parts include process control parts such as PID controller and switch instrument blocks, and function blocks such as cross-limiting and feed sequences, and application-specific functions such as those for boiler control.

All Rights Reserved. Copyright 2002, Yokogawa Electric Corporation

TI 34P02A01-02E

Feb.28,2002-00

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Reliability: Reliability:

Highly Highly Reliable Reliable Architecture Architecture for for Steady Steady Operations Operations

Security Security for for operation operation

Prevention Prevention of of unauthorized unauthorized access access to tothe the network network (by user ID plus password authentication) (by user ID plus password authentication) Limited Limited privileges privileges set set for for the the access access level level assigned assigned to to each each user user Record Record of of user user actions actions

No Noaccess accessright right

Security Security to to minimize minimize impact impact of of faults faults

Risk Risk hedge hedge by by decentralized decentralized installation installation Centralized management of control Centralized management of control information information (no (no impact impact on on the the field field from from HMI HMI failure) failure)

Data Dataacquisition/saving, acquisition/saving, operation, operation,monitoring monitoring

Roles Roles clearly clearly divided divided between between HMI HMI and and controllers controllers
Control, Control,alarm alarm monitoring, monitoring, centralized centralized management managementof ofcontrol control information information

Features Features suitable suitable for for important important equipment control equipment control
Enriched Enriched RAS RAS features features Dual Dual redundant redundant configurations configurations (optional) (optional) Hot-swappable Hot-swappable modules modules for for FCN FCN

Risk Risk hedge hedge by by decentralized decentralized installation installation

Key Keyparts partssuch suchas aspower powersupply supplyand andCPU CPU modules modulesand andcontrol control LAN LAN can canbe be duplexed. duplexed.

Highly Reliable Architecture for Steady Operations

A reliable production system is essential to enable the right products to be manufactured at the right time at the specified quality, cost, and delivery. STARDOM offers operational security, risk hedge, rugged hardware, etc. to ensure steady operations.

Security for Operation

STARDOMs security features can restrict access to writing data, running a program, and so on depending on the access level assigned to individuals, thus protecting the system against unauthorized users and preventing operation mistakes. Even when accessing an on-site system via a Web browser, users must enter their user name and password for authentication.

Reliability of Autonomous Controllers

Distributed installation proposed by autonomous controllers enables functional distribution to facilitate expansion and modification as well as risk hedge to minimize the impact of faults. In addition, the rugged hardware of the controllers, such as memory with ECC and RAS features, and dual-redundant configurations (optional) make them ideal for mission-critical equipment.

All Rights Reserved. Copyright 2002, Yokogawa Electric Corporation

TI 34P02A01-02E

Feb.28,2002-00

Revision Information
Title Manual No. : Introduction to STARDOM : TI 34P02A01-02E
Feb. 2002/1st Edition Newly published

Written by

Open Control Systems Dept. PMK IA Systems Business Div. Published by Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, Japan Printed by Yokogawa Graphic Arts Co., Ltd.

Subject to change without notice.

TI 34P02A01-02E

Feb.28,2002-00