Kinex for Manufacturing Installation and Configuration Guide 1.1
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1 Kinex for Manufacturing Installation and Configuration Guide 1.1
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3 Copyright 2017 PTC Inc. and/or Its Subsidiary Companies. All Rights Reserved. User and training guides and related documentation from PTC Inc. and its subsidiary companies (collectively "PTC") are subject to the copyright laws of the United States and other countries and are provided under a license agreement that restricts copying, disclosure, and use of such documentation. PTC hereby grants to the licensed software user the right to make copies in printed form of this documentation if provided on software media, but only for internal/personal use and in accordance with the license agreement under which the applicable software is licensed. Any copy made shall include the PTC copyright notice and any other proprietary notice provided by PTC. Training materials may not be copied without the express written consent of PTC. This documentation may not be disclosed, transferred, modified, or reduced to any form, including electronic media, or transmitted or made publicly available by any means without the prior written consent of PTC and no authorization is granted to make copies for such purposes. Information described herein is furnished for general information only, is subject to change without notice, and should not be construed as a warranty or commitment by PTC. PTC assumes no responsibility or liability for any errors or inaccuracies that may appear in this document. The software described in this document is provided under written license agreement, contains valuable trade secrets and proprietary information, and is protected by the copyright laws of the United States and other countries. It may not be copied or distributed in any form or medium, disclosed to third parties, or used in any manner not provided for in the software licenses agreement except with written prior approval from PTC. UNAUTHORIZED USE OF SOFTWARE OR ITS DOCUMENTATION CAN RESULT IN CIVIL DAMAGES AND CRIMINAL PROSECUTION. PTC regards software piracy as the crime it is, and we view offenders accordingly. We do not tolerate the piracy of PTC software products, and we pursue (both civilly and criminally) those who do so using all legal means available, including public and private surveillance resources. As part of these efforts, PTC uses data monitoring and scouring technologies to obtain and transmit data on users of illegal copies of our software. This data collection is not performed on users of legally licensed software from PTC and its authorized distributors. If you are using an illegal copy of our software and do not consent to the collection and transmission of such data (including to the United States), cease using the illegal version, and contact PTC to obtain a legally licensed copy. Important Copyright, Trademark, Patent, and Licensing Information: See the About Box, or copyright notice, of your PTC software. UNITED STATES GOVERNMENT RIGHTS PTC software products and software documentation are commercial items as that term is defined at 48 C.F. R Pursuant to Federal Acquisition Regulation (FAR) (a)-(b) (Computer Software) (MAY 2014) for civilian agencies or the Defense Federal Acquisition Regulation Supplement (DFARS) at (a) (Policy) and (a) (Rights in commercial computer software or commercial computer software documentation) (FEB 2014) for the Department of Defense, PTC software products and software documentation are provided to the U.S. Government under the PTC commercial license agreement. Use, duplication or disclosure by the U.S. Government is subject solely to the terms and conditions set forth in the applicable PTC software license agreement. PTC Inc., 140 Kendrick Street, Needham, MA USA
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5 Contents About This Guide...7 Introducing Kinex for Manufacturing...9 Product Requirements...13 Download and Install Kinex for Manufacturing...15 Using the Kinex for Manufacturing Installer...16 Import Kinex for Manufacturing as a ThingWorx Extension...17 Configure Communication with Kepware...19 Getting Started with the Kinex for Manufacturing Apps...23 Configure Users and Roles...24 Create Lines and Assets (Resources)...25 Configure Lines and Assets (Resources)...26 Configure Alerts...33 Configure Trends...37 Known Issues...39 Appendix A.Configure Java for Tomcat
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7 About This Guide This Kinex for Manufacturing guide describes the following: Installation of Kinex for Manufacturing: using the installer or as an extension to ThingWorx Initial configuration steps to get started with Kinex for Manufacturing This guide assumes that the prerequisite products on page 13 are installed and configured, including a Kepware server with connected devices. Comments PTC welcomes your suggestions and comments on its documentation. To submit your feedback, you can send an to documentation@ptc.com. To help us more quickly address your concern, include the name of the PTC product and its release number with your comments. If your comments are about this book, include the Kinex for Manufacturing Installation and Configuration Guide book title. 7
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9 1 Introducing Kinex for Manufacturing Kinex for Manufacturing is a set of role-based starter apps built on ThingWorx that solve common problems in the factory. Today, that suite includes apps for three primary roles in a factory environment: For Controls Engineers Centrally monitor all of your KEPServerEX servers in real-time Be instantly notified when a PLC stops communicating Trend any OPC tag in minutes Create alarms from any OPC tag in minutes For Plant Managers Single source of KPIs and visibility into all lines and machines Create alarms to raise awareness of issues impacting production For Maintenance Engineers/Managers Detect machine anomalies in real-time using PLC data and be instantly notified of issues Kinex for Manufacturing connects to Kepware s KEPServerEX for real-time data, is 100% Web-enabled, and can be installed and configured in less than 15 minutes with zero impact on production. 9
10 App Overview Administration and Configuration Users and Access Control Create users who can login and access the apps. Each user is associated with a role that determines which tiles display for the user. For example, a user in the Controls Engineer role has access to all the apps and can create additional users. For more information, see Configure Users and Roles on page 24. Manage Resources Create the lines and assets (resources) in Kinex for Manufacturing to create your virtual factory. For more information, see Create Lines and Assets (Resources) on page 25 and Configure Lines and Assets (Resources) on page 26. KEPServerEx Monitoring Provides a single web page for monitoring the status of all KEPServerEX connections and devices. If a device stops communicating, this app instantly notifies the Controls Engineer and helps troubleshoot the problem. For more information, see Configure Communication with Kepware on page Kinex for Manufacturing Installation and Configuration Guide
11 Plant Viewer Lists the lines and assets and their status as configured in Manage Resources. To view assets only, see Asset Performance. Trending and Troubleshooting Trend tags from KEPServerEX as well as properties from assets and lines. Trend up to 5 tags or properties on a single trend, and store up to one week of data per trend. For more information, see Configure Trends on page 37. Alert Management Create, view and modify alerts for any tag in KEPServerEX or property from assets and lines. For example, create an alert if the pressure exceeds 100 psi. For more information, see Configure Alerts on page 33. Asset Performance Lists assets and their status as configured in Manage Resources. Asset Performance also displays alerts configured in the Alert Manager. Introducing Kinex for Manufacturing 11
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13 2 Product Requirements Kinex for Manufacturing works in connection with ThingWorx servers and Kepware servers. To use Kinex for Manufacturing, you must have the support identified below. Platform Support Windows Server 2008 R2 and Windows 2012 are recommended and fully tested for production. Server Support ThingWorx server support: Note Applicable when installing Kinex for Manufacturing as an extension. When using the installer, ThingWorx is installed for you. ThingWorx with PostgresSQL database For information, see Installing ThingWorx 7.3. Kepware and ThingWorx can be on the same machine, but for production, they should be on separate machines. Kepware server support: KEPServerEX Version 6, which includes ThingWorx Native Interface For more information, see KEPServerEx Version 6 Install Guide. 13
14 Note This release of Kinex for Manufacturing supports up to 10 KEPServerEX installations. Client Browser Support Chrome 51 Firefox ESR 47+ Internet Explorer 11 When displaying mashups in Internet Explorer 11, ensure your compatibility view settings are set as follows: 1. In the upper-right corner of the browser window, click the tools icon. 2. Select Compatibility View Settings. 3. Clear the following check boxes: Display intranet site in compatibility view Use Microsoft compatibility lists 14 Kinex for Manufacturing Installation and Configuration Guide
15 3 Download and Install Kinex for Manufacturing Using the Kinex for Manufacturing Installer...16 Import Kinex for Manufacturing as a ThingWorx Extension...17 Separate processes guide you through the installation. Select one of the following: Using the Kinex for Manufacturing Installer on page 16 Import Kinex for Manufacturing as a ThingWorx Extension on page 17 15
16 Using the Kinex for Manufacturing Installer Kinex for Manufacturing bundles the following in the installer: Java 8 update 111 ThingWorx PostgreSQL PTC Servlet Engine Follow these steps for the Kinex for Manufacturing installer. 1. Extract kinex-manufacturing-installer.zip. 2. From the extracted folder, locate and launch setup.exe. 3. During the installation: Agree to the beta terms and conditions. Specify the location where Kinex for Manufacturing and its components will be installed. Specify the PostgreSQL password and communication ports. If you receive a Windows alert saying a firewall has blocked the setup, allow access to all networks. If you install on an unsupported platform, such as Windows 7, a warning could appear; however, you can proceed with the installation. 4. Select Configure to complete the following: Configure the PostgreSQL database. Configure PTC Servlet Engine. Install ThingWorx. Install Kinex for Manufacturing. 5. During the configuration: Specify the ThingWorx server Administrator password. Specify the ThingWorx server communication port number. 6. Next, go to Configure Communication with Kepware on page Kinex for Manufacturing Installation and Configuration Guide
17 Note After installation, a shortcut is created on your desktop and the product is available from your Start menu. To uninstall, select uninstall.exe in the extracted folder. Import Kinex for Manufacturing as a ThingWorx Extension If you are an experienced ThingWorx user and already have ThingWorx installed, the easiest way to get started with Kinex for Manufacturing is to download and import the extensions. Prerequisites Review Product Requirements on page 13 before proceeding. For example, Kinex for Manufacturing is supported for ThingWorx Importing the extension on later versions of ThingWorx is not supported. 1. Follow the instructions to Configure Java for Tomcat on page Download and unzip the content of the following files: kinex-for-manufacturing-{version}-extensiondependency.zip kinex-for-manufacturing-{version}-extension.zip 3. From ThingWorx Composer, navigate to Import/Export Import. 4. In the Import Extensions window, navigate to kinex-formanufacturing-{version}-extension-dependency.zip. 5. Click Import and refresh the window if prompted. 6. Again select Import/Export Import. 7. In the Import Extensions window, navigate to kinex-formanufacturing-{version}-extension.zip. 8. Click Import and refresh the window if prompted. To view the extensions after the import is complete, select Import/Export Manage. Download and Install Kinex for Manufacturing 17
18 Verify the Installation Now that Kinex for Manufacturing is installed, verify that you can access the apps. Go to the following URL on the ThingWorx server: Thingworx/Runtime/index.html#master=PTC.FactoryConsole.Master&mashup= PTC.FactoryConsole Note Change the port number as needed. For example, localhost:<port#>/thingworx/. The default login and password are Administrator and <your password> respectively. 18 Kinex for Manufacturing Installation and Configuration Guide
19 4 Configure Communication with Kepware This connection with Kepware provides the data needed by the Kinex for Manufacturing apps. Kepware can be on the same server or a different server than ThingWorx. One or more KEPServerEX servers can be connected. 1. When using the Kinex for Manufacturing installer, the last page includes a link to the login page where you create your first Kepware server connection. Enter a server or Thing name. Then follow the instructions available on the setup page. This server or Thing name needs to match the field specified in the following location in KSE: Configuration Project Project properties Thingworx configuration 2. In Kepware, confirm a connection to ThingWorx displays in the Event column. In KEPServerEX Configuration, confirm a connection to ThingWorx displays in the Event column. 19
20 If you receive an error message indicating that the connection to the ThingWorx platform failed and could not initialize a secure socket connection, the following steps: Verify the host, port, resource, and application key are all valid and correct Verify the host machine can reach the composer on the ThingWorx platform Verify that the proper certificate settings are enabled 3. Launch Kinex for Manufacturing from the icon on your desktop or the Start menu. 4. Click KEPServerEX Monitoring. 20 Kinex for Manufacturing Installation and Configuration Guide
21 5. The server you connected displays in the Connected Servers list. Select it and click discover devices. The action scans the server and creates the devices in Kinex for Manufacturing. Repeat this action as devices are added and removed from KEPServerEX. Configure Communication with Kepware 21
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23 5 Getting Started with the Kinex for Manufacturing Apps Configure Users and Roles...24 Create Lines and Assets (Resources)...25 Configure Lines and Assets (Resources)...26 Configure Alerts...33 Configure Trends...37 This is the suggested workflow for getting started with Kinex for Manufacturing. 23
24 Configure Users and Roles 1. Select Administration and Configuration Users and Access Control. 2. Click create user. 3. Enter information for the users. Each role is described below. Begin by creating a user for yourself in the Controls Engineer role. Role Controls Engineer Production Manager Quality Engineer Maintenance Manager Maintenance Engineer Access All apps Plant Viewer Alert Monitoring Plant Viewer Trending and Troubleshooting Alert Monitoring Manage Resources Trending and Troubleshooting Alert Management Asset Performance Manage Resources Trending and Troubleshooting Alert Management Asset Performance 24 Kinex for Manufacturing Installation and Configuration Guide
25 Create Lines and Assets (Resources) 1. Click Administration and Configuration Manage Resources. 2. Create new lines and assets. a. Click new resource. b. Create lines and assets. 3. Relate asset to the line. a. Select an asset in Resources table and click configure resource. b. In the Related Lines table on the General Information page, relate the line to the asset. 4. Continue to Configure Lines and Assets (Resources) on page 26. Getting Started with the Kinex for Manufacturing Apps 25
26 Configure Lines and Assets (Resources) Once lines and assets are created, configure the properties, status, and performance metrics. 1. Click Administration and Configuration Manage Resources. 2. Select your asset or line from the Resources table and click configure resource. 3. From the details page of the asset or line, complete the actions on each page as described in the sections below. Here is the suggested workflow. Note This assumes you have related assets to your lines as described in Create Lines and Assets (Resources) on page 25. a. Create properties on your assets. b. Define the status for your assets based on the tags selected from KEPServerEx. c. Define performance metrics for your assets (optional). d. Create properties for your line. e. Define the status for your line based on the assets in the line. f. Define performance metrics for your line. Additional Properties Add properties or tags from Kepware. You can add: static properties by specifying the name, type and value properties that pull the value from a Kepware tag The following example pulls the temperature tag from Kepware. 26 Kinex for Manufacturing Installation and Configuration Guide
27 1. Click new property. 2. Enter information in related fields. For Value, click the icon to browse for a tag. 3. Locate and select the information from your Kepware server. Status For an asset: 1. Use the arrows in the Define Status header to place the states in the order they are checked by the system. Getting Started with the Kinex for Manufacturing Apps 27
28 The numbers associated with the state name, for example (1), do not apply to the order. They are used when you create a new alert on page For each state, enter an expression. You can manually enter the expression or browse to select tags from your Kepware server. This asset example shows the states set using the temperature and humidity properties. For lines, the expressions can relate to the children, or assets, of the line. 28 Kinex for Manufacturing Installation and Configuration Guide
29 This line example shows that the line is in planned downtime if either of the two assets in the line are in planned downtime. The expressions were copied from the planned downtime expressions for each asset. 3. Save the table. Getting Started with the Kinex for Manufacturing Apps 29
30 Performance Metrics The procedure below describes how to enter performance metrics for your lines and assets. The help icons in each field state the equations used. Note This procedure assumes you have a Kepware tag from which you can access the number of good parts and bad parts for the day. 1. Good Count For assets, enter or browse for the Kepware tag that identifies good parts for the asset. 30 Kinex for Manufacturing Installation and Configuration Guide
31 For lines, enter the good counts for each of the assets, or children, of the line. 2. Total Count For assets, enter or browse for your bad count and then add your good count. You can copy and paste the good count from the previous field. For lines, enter the good count and bad count for all assets, or children, of the line. Getting Started with the Kinex for Manufacturing Apps 31
32 3. Ideal Run Rate Identify how quickly your factory would be producing parts for the asset or line in an ideal situation. Enter parts per minute. 4. Click Save. 5. Go to Plant Viewer and Asset Performance to view the performance metrics you have defined for the lines and assets. Note Immediately after configuring performance metrics, low performance metrics are to be expected. 32 Kinex for Manufacturing Installation and Configuration Guide
33 Configure Alerts You can create alerts using the status expressions set when you Configure Lines and Assets (Resources) on page Go to Alert Management Alert Editing. 2. Click create. 3. Select the resource on which you want to create the alert. Choose from the following: a line or asset you created in Kinex for Manufacturing a device any KEPServerEx Getting Started with the Kinex for Manufacturing Apps 33
34 4. Select the property used for the alert. This example uses status. 5. Create the alert. For Value, use the numbers listed in the description. 34 Kinex for Manufacturing Installation and Configuration Guide
35 6. To view alerts: a. Go to Alert Monitoring. or Go to Asset Performance and click the alert icon next to the asset with the alert. b. The new alert appears in the Alert Monitor. Getting Started with the Kinex for Manufacturing Apps 35
36 Note After creating the alert, it may take a minute before the alert appears. 7. To acknowledge the alert, click. Once an alert has been acknowledged, a checkmark appears in the table and it no longer sends out s and text messages. 36 Kinex for Manufacturing Installation and Configuration Guide
37 Configure Trends Each trend you create in Kinex for Manufacturing tracks up to five tags or properties for a given resource (line or asset). To create a trend: 1. Click Trending and Troubleshooting. 2. Click new trend. 3. In the New Trend window, enter a name and optionally, a description. 4. Select the type and resource. Getting Started with the Kinex for Manufacturing Apps 37
38 5. Select up to 5 properties or tags to trend for the selected resource. 6. Once the trend is created, you can view any of the selected properties over different lengths of time. 38 Kinex for Manufacturing Installation and Configuration Guide
39 6 Known Issues The following known issues exist in this release of Kinex for Manufacturing. Performance and scalability Kinex for Manufacturing supports a maximum of 250 devices per server. Discovering devices for a specific server may take several minutes for a large number of devices. Update of KEPServerEX system tags only occurs when non-system tags associated to the server are monitored. To monitor a non-system tag, create a trend in Trending and Troubleshooting and add any tag from any devices. System tags are found in the _System and _Statistics tag groups in KEPServerEX. 39
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41 A Configure Java for Tomcat Note This procedure applies when installing Kinex for Manufacturing as an extension. When using the installer, Java and Tomcat are installed and configured for you. To change the Tomcat configuration, follow these steps: 1. From the Start menu, launch the Configure Tomcat program. 2. Under the Java tab, add the following line in the Java Options: Note: These Java options are recommended for ThingWorx: -Dserver -Dd64 -XX:+UseNUMA -XX:+UseConcMarkSweepGC -Dfile.encoding=UTF-8 3. Define values in the Initial memory pool and Maximum memory pool fields. Here are the recommended values: Initial memory pool: 5120 Maximum memory pool:
42 4. Increase the default cache settings that affect static file caching by adding the following line within the tags in the $TOMCAT_HOME\conf\ context.xml file: <Resources cachemaxsize="501200" cacheobjectmaxsize="2048" cachettl="60000"/> 5. Go to the location of the Tomcat installation. a. Open the server.xml file in the conf folder. For example, $TOMCAT_ HOME\conf\server.xml. b. Replace HTTP/1.1 with protocol= "org.apache.coyote.http1 1.Http11NioProtocol". 6. Save and close the file. 42 Kinex for Manufacturing Installation and Configuration Guide
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