Manufacturing Execution System and Process Control System – POSCO

POSCO chose Altibase over Oracle TimesTen and IBM solidDB to bolster its entire manufacturing process and real time sensor data operations, vastly enhancing on-time delivery, customer satisfaction and profit.

Use Case: Manufacturing Equipment System (MES)

Current Customers: POSCO and SeAH Besteel

Industry: Manufacturing

Who

POSCO is a global leader in steel manufacturing.

Problem

POSCO could not promptly deliver products to its customers as its legacy system was becoming obsolete.

  • POSCO required seamless operation of separate systems, but its legacy DBMS could not handle it.
  • Marked by data redundancy, low performance and increasing resource deterioration, POSCO’s Manufacturing Execution System (MES) and Process Control System (PCS) ran inefficiently.
  • POSCO was losing its stronghold on competition due to its inability to keep deadlines on product delivery. Increasing demands on order flow worsened the situation.
  • A critical step toward resolution was to integrate MES and PCS, but this necessitated an upgrade to POSCO’s train control system. The upgrade required a DBMS with HA and the ability to quickly process massive volumes of data produced from its molten metal transporting trains at its 5 blast furnaces.[1]

Solution

POSCO deployed Altibase for its in-memory database feature after benchmark tests with Oracle TimesTen and IBM SolidDB.[2] Altibase provided POSCO with consistency, high speed and superior reliability with HA feature. POSCO has utilized Altibase adapter for Oracle, OraAdapter, which effortlessly integrates data between Oracle and Altibase.[3]

Results

  • POSCO is endowed with its revamped train control system. Built on Altibase after only 5 months of development time, POSCO has industry leading flexibility, reliability and performance.
  • POSCO has full control over its metal transporting trains that are armed with the ability to store and analyze 40,000 bits of sensor data per second. The data is collected from 4,000 railroad sensors and readied for instant availability.
  • POSCO supplies products to customers on time and can easily scale with demand.
  • POSCO has initiated integration of MES and PCS bolstered by Altibase’s HA and reliability with its simple user interface, saving money and time.[4]
  • The MES and PCS integration has eliminated redundant data and has drastically reduced the number of technical failure points, resulting in projected cost savings of over $300,000 per year.

 

Technical Details – Manufacturing Execution System and Process Control System

POSCO achieved exceptional results by leveraging key features of Altibase, specifically in the areas of high performance and HA.

 

High Performance

POSCO was using a control system for controlling the flow of molten metal between its blast furnaces and production lines. With a legacy on-disk DBMS in its back-end, the capacity of control system for collecting information from sensors was 400 TPS which was inadequate for detecting and responding to process status changes in real time.

POSCO decided to replace the legacy on-disk DBMS with a high performance in-memory DBMS. To determine the best alternative technology, POSCO conducted benchmark tests with Oracle TimesTen, IBM solidDB and Altibase. POSCO’s benchmark tests focused on four primary requirements: real time DBMS performance, interoperability with WebLogic application server, failover functionality and interoperability with Oracle on-disk DBMS for data synchronization.

Altibase was the clear winner by meeting and exceeding all four primary requirements. For the real time DBMS performance requirement, Altibase provided POSCO with unsurpassed performance of 2,500 TPS. As a result, POSCO officially announced that it would use Altibase for production and manufacturing management purposes in August, 2011. Since then, POSCO has adopted Altibase for other internal projects including a railroad control system.

 

HA

In addition to the performance issues with the increased volumes of transactions, POSCO’s legacy on-disk database had reliability and stability issues, resulting in system outages.

Using the Altibase’s built-in replication feature, POSCO utilized Altibase based on active-standby HA architecture. In this architecture, Altibase replication feature maintains an up-to-date live database on the standby server. In the event of unexpected master server unavailability, immediate service resumption initiates from an identical database on an alternate server. POSCO is empowered by a non-stop operating environment with improved reliability and fault-tolerance. Altibase has never failed and continues to provide reliable service since it was first put in production by POSCO in May, 2011.

Manufacturing Execution System


[1] One of POSCO’s 5 blast furnaces possesses the greatest production capacity in the world.

[2] Altibase outperformed Oracle TimesTen in speed and reliability while IBM SolidDB exited the benchmark test midway.

[3] Altibase has a built-in functionality (a custom tool) to apply data from Altibase to Oracle.

[4] Altibase’s built-in replication feature enables business continuity with flexible HA configuration.

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