Manufacturing Execution System (MES)

Virtual Environment

Implementation Guide

Version 6.0
June, 2018
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 MES Virtual Environment Implementation Guide

Contents
Chapter 1 Getting Started..................................................................................................... 5
Virtualization Overview .............................................................................................................. 5
Using This Guide ...................................................................................................................... 5
Understanding Virtualization ...................................................................................................... 5
Definitions........................................................................................................................... 6

Chapter 2 Application Configuration ................................................................................... 7

E vents ...................................................................................................................................... 7
Application Server Configuration Details ..................................................................................... 8

Chapter 3 Recovery Time Objective and Recovery Point Objective ............................. 9

Key Performance Indicators Used .............................................................................................. 9
RTO Measurement.................................................................................................................... 9
RPO Measurement ................................................................................................................... 9

Chapter 4 Configuration Information for a VMware Environment ................................ 11

VMware Environment Configuration Overview .......................................................................... 11
Host Hardware for VMware Servers ......................................................................................... 11
Guest Operating Systems (Virtual Machines) ............................................................................ 12
Shared Disk Storage/SAN ....................................................................................................... 12
Physical Machines (External) ................................................................................................... 12

Chapter 5 Scenarios and Observations in the VMware Virtual Environment............. 15

VMware Scenarios and Obs ervations Overview ........................................................................ 15
Live Migration (Using vMotion) ................................................................................................. 15
Observations .................................................................................................................... 15
Failover (Triggered by Powering Off the Host Machine) ....................................................... 16
Notes ............................................................................................................................... 16
Observations .................................................................................................................... 16

Chapter 6 Configuration Information for a Hyper-V Environment ................................ 17

Hyper-V Environment Configuration Overview .......................................................................... 17
Host Machines ........................................................................................................................ 17
Virtual Machines ..................................................................................................................... 18
Physical Machines .................................................................................................................. 18

Chapter 7 Scenarios and Observations in the HyperV Virtual Environment .............. 21

Hyper-V Scenarios and Obs ervations Overview ........................................................................ 21
Live Migration ......................................................................................................................... 21

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Failover (Triggered by Powering Off the Host Machine) ....................................................... 22

Observations .................................................................................................................... 22
Failover (Triggered by Disconnecting the Host Machine from the Network) ........................... 22
Observations .................................................................................................................... 22

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C HAPTER 1
Getting Started
In This Chapter
Virtualization Overview.................................................................................................................... 5
Using This Guide ............................................................................................................................ 5
Understanding Virtualization ............................................................................................................ 5

Virtualization Overview
Virtualization technologies are becoming a high priority for IT administrat ors and managers, software
and systems engineers, plant managers, software developers, and system integrat ors.
Mission-critical operations in both small- and large-scale organizations demand availability—defined as
the ability of the user community to access the system—along with dependable recovery from natural or
man-made disasters. Virtualization technologies provide a plat form for High A vailability solutions.

Using This Guide

The purpose of this guide is to help you to implement Manufacturing Execution System (MES) in a
virtualized environment, including:
 Implementing High A vailability (Live Migration and Failover) using VMware technology
 Implementing High A vailability (Live Migration and Failover) using Windows Server virtualization
technologies such as Hyper-V
This chapter int roduces and defines virtualization concepts.
Subsequent chapters describe how MES was configured in a virt ualized environment for a High
A vailability qualification. They also describe test results for the suggested configurations using bot h
VMware and Hyper-V technology.
Subsequent chapters also provide test and performance metrics for a wide variety of system
configurations, including Recovery Time Objective (RTO) and Recovery Point Objective (RPO).

Understanding Virtualization
Virtualization is the creation of an abstracted or simulated—virtual, rather than actual—version of
something, such as an operating system, server, net work resource, or storage device. Virtualization
technology abstracts the hardware from the software, extending the life cycle of a software platform.
In virtualization, a single piece of hardware, such as a server, hosts and coordinates multiple guest
operating systems. No guest operating system is aware that it is sharing res ources and running on a
layer of virtualization software rather than directly on the host hardware. Each guest operating system
appears as a complete, hardware-based OS to the applications running on it.

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MES Virtual Environment Implementation Guide Getting Started

Definitions
This implementation guide assumes that you and your organization have done the necessary research
and analysis and have made the decision to implement MES in a virtualized environment that will replace
the need for physical comput ers and instead run them in a virtualized environment. Such an environment
can take advant age of advanced virtualization features, including High A vailability. In that context, we’ll
define the terms as follows:
 Virtualization in MES terms can be defined as creating a virtual, rather than real, server for one of the
MES servers, including the Middleware server and the Application Object server, as well as the
network resources to support the server.
 High A vailability in MES can be defined as the way to make any of the MES servers available without
interruption during production operations. In this virtualization testing, we chose the most critical
server—t he MES Middleware server.
While these definitions are general and allow for a variety of High A vailability designs, this
implementation guide focuses on virtualization as an indispensable element in creating the redundancy
necessary for highly available MES solutions.
The virtualized environment described in this guide is based on Microsoft Hyper-V technology
incorporated in the Windows Server 2008 R2 operating system, and on VMware’s virtualization platform
vSphere 5.0.
MES is tested on newer versions of vS phere as updates are released by VMware. Microsoft Hyper-V is
not routinely tested. As the virtualization technology is invisible to the MES software, there is no specific
version support statement for VMware vSphere or Microsoft Hyper -V. The timing tests as described in
this document have not been re-run on newer versions of either virtualization platform.

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C HAPTER 2
Application Configuration
To test the MES High A vailability implementation in a virtualized environment, a predictable MES
application was developed. A description of the application used for the validation and testing of the
virtualized environments described in this guide —a machine shop application—is provided in the
following topics.

In This Chapter
E vents ........................................................................................................................................... 7
Application Server Configuration Details ........................................................................................... 8

Events
The machine shop application was based on a set of ArchestrA object templates with pre -configured
scripts that trigger events at regular intervals. This made the events, and thereby the data logged in the
MES databas e, predictable. Any values related to events (e.g., good production) are set to a consta nt
value.
The following events were triggered by the machine shop application.
Hourly Events
 Change state of mac hine to a running state
 Create job
 Receive inventory
 Stop job
 Reset event commands if in error
 Reset stop job commands if in error
 Start job
 Change state of mac hine to a running state
Minutely Events
 Add good production
 Add bad production
 Add consumption
 Reset various event commands if in error
This configuration guarantees that at any given second one of each minutely event will be triggered if
there is a corresponding MES object for that second. This ensures that when migration (Live
Migration/failover) is triggered, the configured events are being exercised.
Also, the MES database was pre-populated with one year’s wort h of data prior to running through the
various scenarios to ensure that the test scenarios were run on a typically loaded system.

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MES Virtual Environment Implementation Guide Application Configuration

Application Server Configuration Details

 Total number of engines: 1
 Number of objects under engine: 182:
o 61 UDOs (us er-defined objects)
o 61 OCOs (MES operations capability objects)
o 60 UCOs (MES utilization capability objects)
There were a total of 60 machines (each machine/MES entity has one UCO, one OCO) used in the
VMware environment setup and 40 machines used in the Hyper-V environment setup.
Due to different hardware, a different number of entities was used in the Hyper-V and VMware
environments to establish sustained load for the test prior to executing the scenarios. However, this does
not imply a difference in performance for Hyper-V and VMware.
The following figure shows the Deployment view for the machines set up for the testing. The specifics of
the machines varies, but this figure shows the basic structure.

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C HAPTER 3
Recovery Time Objective and Recovery
Point Objective
In This Chapter
Key Performance Indicators Used .................................................................................................... 9
RTO Measurement ......................................................................................................................... 9
RPO Measurement ......................................................................................................................... 9

Key Performance Indicators Used

For this testing, two key performance indicators (KPIs) were used to define the performance of the test
scenarios:
 The Recovery Time Objective (RTO) is the duration of time within which the virtualized server must
be restored to its service level after a disaster or ot her disruption t o avoid a break in plant operations.
 A Recovery Point Objective (RPO) is defined in business continuity planning. It is the maximum
tolerable period in which dat a from the virtualiz ed server might be lost due to a major incident.
The RTO and RPO depend on factors of the host server such as storage I/O performance, CPU
utilization, memory usage, and net work usage at the time of failover/migration activity.
The following topics describe how RTO and RPO were measured for the MES middleware virt ualized
server configuration.

RTO Measurement
The RTO measurement is the time interval during which the MES Middleware server is not available:
RTO = RTO (T2) – RTO (T1)
where
 T1 = The time-stamp when the MES Middleware service cannot be detected. This also can be the
time-stamp for when the "fault" is introduced into the system (e.g., Live Migration cutover, power off,
network disabled or an operating system failure).
 T2 = The time-stamp when the MES Middleware service is detected on the target machine (by using
the servic es log on the target machine to determine T2).
If more than one clock is involved, be sure to either synchronize the clocks or understand the offset. In
addition, MES Middleware service was monitored using Windows Performance Monitor (P erfMon).

RPO Measurement
The RP O measurement is the time interval during which there is no data being entered in the MES
database.
RPO = RPO (T2) – RPO (T1)
where

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MES Virtual Environment Implementation Guide Recovery Time Objective and Recovery Point Objective

 T1 = The time-stamp of the last record entered in the MES database at or before RTO (T1); that is,
(RPO (T1) <= RTO (T1)).
 T2 = The time-stamp of the first record entered in the MES database at or after RTO (T2); that is,
(RPO (T2) >= RTO (T2)).
It is possible that RPO is less than RTO, since there is a client middleware layer that allows for
serialization of events while the MES Middleware service is unavailable. If RPO = 0, this implies that no
events were missed.
Custom SQL queries were developed and run against the MES database to determine the time-stamp of
the "last" record before an HA DR fault and the "first" record following an HA DR fault.

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C HAPTER 4
Configuration Information for a VMware
Environment
In This Chapter
VMware Environment Configuration Overview ................................................................................ 11
Host Hardware for VMware Servers ............................................................................................... 11
Guest Operating Systems (Virtual Machines) .................................................................................. 12
Shared Disk Storage/SAN ............................................................................................................. 12
Physical Machines (External)......................................................................................................... 12

VMware Environment Configuration Overview

The following information is provided to help you set up and implement High A vailability for MES using
VMware.
For basic procedures about how to install VMware products, see product support and user
documentation at http://www.vmware.com/.
For detailed procedures to implement High A vailability in a VMware environment with ArchestrA System
Platform, refer to the ArchestrA System Platform Virt ual Implementation Guide.

Host Hardware for VMware Servers

Two VMware Servers were used to configure the failover cluster for this qualific ation.

Processor 2.79-GHz Intel Quad Core E5405 processors (hyper-threaded)

Operating System VMware ES Xi 5. 0

Memory 48 GB

Storage SAN with a 1-TB storage disk (single SCS I Disk with virtual partition)

NIC Four Broadcom Net Xtreme II BCM5709 1000 BaseT cards

Network 4 network adaptors [1 virtual machine (VM) network, 1 VMotion network, 1

management net work, and 1 unused network]

Storage controller Dell SAS 5/E Adapter.

Data transfer rate: Up to 300 MBps per link in each direction.

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MES Virtual Environment Implementation Guide Configuration Information for a VMware Environment

Guest Operating Systems (Virtual Machines)

Virtual Machine 1: MES Middleware Server
Processor Intel Xeon X5560 @ 2.80GHz, 2.79 GHz (2 processors)

Operating System Windows Server 2008 R2 Standard, SP1 64 -bit

Memory 4 GB

Storage 39.8 GB

Product Installed MES 2012 (Middleware, MES Service, MES Client, MES Configurator, MES
Operator, and MES Supervisor)

Virtual Machine 2: Application Server

Processor Intel Xeon X5560 @ 2.80 GHz, 2.79 GHz (2 processors)

Operating System Windows Server 2008 Standard SP2 32-bit

Memory 4 GB

Storage 39.9 GB

Product Installed Application Server - ASP2012 - IDE and Bootstrap, Applic ation Server Runtime,
and deployed MES application objects

Shared Disk Storage/SAN

Base Unit PowerVault MD3000 external RAID array with 2 dual-port controllers
Hard Drive Controller Four SAS 5/E Host bust adapters PCI Express

Physical Machines (External)

The physical machines used and their configurations are provided below. Virtualization of these
machines could have been done, but we chose t o keep them on real machines to concentrate t he testing
on the MES middleware and Application Server hosting MES objects.
Physical Machine 1: Application Server Galaxy Repository

Processor Intel Core 2 Quad CPU Q9400 @ 2.66 GHz, 2.66 GHz

Operating System Windows Server 2008 Standard SP2 32-bit

Memory 4 GB

Storage 149 GB

NIC Intel 82567LM-3 Gigabit Network Adapter

Network LAN

Product Installed Application Server – ASP2012, Galaxy Repository, IDE and SQL Server 2008
SP3

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Physical Machine 2: MES Database

Processor CPU Intel Xeon CP U E7340 @ 2. 40 GHz, 2.39 GHz (4 processors)

Operating System Windows Server 2008 Standard, SP2 64-bit

Memory 128 GB

Storage 2 disks, 48.8 GB/1.0 TB

NIC Intel PRO/1000 MT Network Adapter

Network LAN

Product Installed MES databas e, SQL Server 2008 SP3

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 MES Virtual Environment Implementation Guide

C HAPTER 5
Scenarios and Observations in the VMware
Virtual Environment
In This Chapter
VMware Scenarios and Obs ervations Overview .............................................................................. 15
Live Migration (Using vMotion)....................................................................................................... 15

VMware Scenarios and Observations Overview

The machine hosting the MES Middleware server and the MES Service, and the machine hosting the
Application Object Server running the machine shop application, were subject to Live Migration and
failover. The various scenarios, measurements, and observations are provided in the following topics.

Live Migration (Using vMotion)

Applications Scenario RTO (se c) RPO (sec)

MES Service and Middleware server Top of the minute 1 0

MES Service and Middleware server Top of the hour 1 0

MES Service and Middleware server Top of the day 1 0

MES Service and Middleware server During shift change 1 0

MES Service and Middleware server When an archive job is 0 0

in progress

MES Service and Middleware server When a purge job is in 1 0

progress

Application Server hosting the mac hine shop During normal 1 0

application execution

Observations
 After the migration, the MES transactions continued to execute correctly.

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MES Virtual Environment Implementation Guide Scenarios and Observations in the VMware Virtual Environment

 There were no errors/warnings in the SMC, Windows E vents Log, or SQL Server loggers after Live
Migration.
 There was no transaction/data loss after Live Migration.
 Both MES Client and the objects retained the connection to the MES middleware after the Live
Migration.

Failover (Triggered by Powering Off the Host Machine)

Applications Scenario RTO (se c) RPO (sec)

MES Service and Middleware server Top of the minute 138 180

MES Service and Middleware server When an Arc hive job is in 145 180
progress

MES Service and Middleware server When a Purge job is in 138 240
progress

Application Server hosting the mac hine During normal execution 138 300
shop application
MES Service, Middleware server, and During normal execution 144 (A ppObject) *
Application Server hosting the mac hine
308 (middleware)
shop application

*The RPO is undefined as the Application Server Objects had to be redeployed before they were functional.

Notes
 The RTO is also influenced by the Windows delay during start up, during which the system waits
approximately 30 seconds for the user to select normal or safe mode start up.

Observations
While the MES middleware alone fails over, the ArchestrA log on the Application Server machine logs
warnings and errors indicating the inability of the objects to communicate with the middleware while the
middleware is unavailable. However, the MES objects recover after the failover and no more
errors/warnings are reported in the Logger.
 The Archive operation is aborted aft er the middleware failover and the same is indicated against the
job in the client and the ArchestrA log on the Middleware server.
 The Purge operation is aborted after the middleware failover and the same is indicated against the
job in the client and the ArchestrA log on the Middleware server.
 The databas e is left undisturbed.
 When the Application Server alone fails over, the middleware logs Lost connection to subscription
warnings. There are a few warnings and errors in the Application Server machine; however, the
Application Server stabilizes event ually (as defined by the RTO).
 When bot h the Application Server and the middleware fail over, the middleware comes back online
and does not log any warnings or errors. However, the Application Server is unable to recover wit h
multiple warnings and errors logged to the Arc hestrA logger.

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C HAPTER 6
Configuration Information for a Hyper-V
Environment
In This Chapter
Hyper-V Environment Configuration Overview ................................................................................ 17
Host Machines.............................................................................................................................. 17
Virtual Machines ........................................................................................................................... 18
Physical Machines ........................................................................................................................ 18

Hyper-V Environment Configuration Overview

The following configuration information is provided to help you set up and implement High A vailability for
MES using Hyper-V.
For detailed proc edures about how to implement High A vailability in a Hyper-V environment with
ArchestrA System Platform, refer to the ArchestrA System Platform Virtual Implementation Guide.

Host Machines
Primary Hyper-V Machine

Processor Intel Xeon x5650 @ 2.67 GHz, 2.67 GHz

Operating System Microsoft Windows Enterprise 2008 R2 SP1

Memory 96 GB

Storage 1 TB storage disk (External Machine)

NIC Two BroadCom Net Xtreme Gigabit Ethernet adapters

Two Intel PRO/1000 P T Dual Port Server Adapter cards

Network 4 network adaptors (2 public/ virtual net works; 1 iSCSI; and 1 private)

Secondary Hyper-V Machine

Processor Intel Xeon x5650 @ 2.67 GHz, 2.67 GHz

Operating System Microsoft Windows Enterprise 2008 R2 SP1
Memory 96 GB
Storage 1 TB storage disk (external machine)
NIC Two BroadCom Net Xtreme Gigabit Ethernet adapters
Two Intel PRO/1000 P T Dual Port Server Adapter cards

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MES Virtual Environment Implementation Guide Configuration Information for a Hyper-V En vironment

Network 4 network adapters (2 public/ virtual net works; 1 iSCSI; and 1 private)

Notes
 For the Hyper-V hosts to function optimally, the server should have the same processor, RAM,
storage, and service pack level. Though the different host machine configurations are supported,
they will impact the performance during failovers.
 Two Hyper-V hosts were used to configure the failover cluster.

Virtual Machines
Virtual Machine 1: MES Middleware Server

Processor Intel Xeon x5650 @ 2.67 GHz, 2.67 GHz

Operating System Microsoft Windows 2008 E NT SP2

Memory 8 GB

Storage 80 GB

Products Installed MES 2012 (MES Middleware, MES Service, MES Client, MES Configurator,
MES Operator, and MES Supervis or)

Virtual Machine 2: Application Server

Processor Intel Xeon x5650 @ 2.67 GHz 2.67 GHz

Operating System Microsoft Windows 2008 E NT SP2

Memory 4 GB

Storage 100 GB

Products Installed Application Server – ASP2012 R2 - IDE & Bootstrap, GR and Application Server
Runtime, and deployed MES application objects

Physical Machines
The configurations of the physical machines that were used are provided in the following topics.
Virtualization of thes e machines could have been done, but it was decided to keep them on real
machines to concentrate the qualification on the virtualized MES functionality.
Physical Machine 1: Galaxy Repository

Processor Intel Core2 Quad CPU Q9400 @2.66 GHz, 2.66 GHz

Operating System Microsoft Windows 2008 R2 Standard SP1

Memory 4 GB

Storage 150 GB

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NIC Intel 82567LM-3 Gigabit Network Adapter

Network LAN

Products Installed ASP2012 R2, Galaxy Repository, IDE, and SQL Server 2008 R2 SP1

Physical Machine 2: MES Database

Processor Intel Xeon CP U E7340 @2.40 GHz, 2.40 GHz

Operating System Microsoft Windows 2008 Standard 32-bit

Memory 128 GB

Storage 1 TB

NIC Broadcom BCM5708C Net Xtreme II GigE Network Adapter

Network LAN

Products Installed MES Database, SQL Server 2008 ENT R2 SP2

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 MES Virtual Environment Implementation Guide

C HAPTER 7
Scenarios and Observations in the HyperV
Virtual Environment
In This Chapter
Hyper-V Scenarios and Obs ervations Overview.............................................................................. 21
Live Migration ............................................................................................................................... 21

Hyper-V Scenarios and Observations Overview

The machine hosting the MES Middleware server and the MES Service, and the machine hosting the
Application object server running the machine shop application, were subject to Live Migration and
failover. The various scenarios, measurements, and observations are provided in the following topics.

Live Migration

Applications Scenario RTO (se c) RPO (sec)

MES Service and Middleware server Top of the minute 14 0

MES Service and Middleware server Top of the hour 12* 0
MES Service and Middleware server Top of the day 4 0
MES Service and Middleware server During shift change 12 0
Application Object Server hosting the machine During normal 4 0
shop application execution
MES Service and Middleware server When an archive job is 9 0
in progress
MES Service and Middleware server When a purge job is in 11 0
progress
*There w as one warning in Application Server SMC immediately follow ing the Liv e Migration at top of the hour:
Had trouble closing connection on Dispose - The socket transfer timed out after 00:00:05. You have exceeded the timeout set
on your binding. The time allotted to this operation may have been a portion of a longer timeout.
There were two warnings in Middlew are node SMC immediately follow ing the Live Migration at top of the hour:
SyncCmdSvc.ExecCmd - clientId [Middlew areVM.DefaultDomain.28] --> Violation of PRIMARY KEY constraint
'PK_tpm_stat'. Cannot insert duplicate key in object 'dbo.tpm_stat'… .

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MES Virtual Environment Implementation Guide Scenarios and Observations in the HyperV Virtual Environment

Failover (Triggered by Powering Off the Host Machine)

Applications Scenario RTO (se c) RPO (sec)

MES Service and Middleware server Top of the minute 88 60

Observations
 It is recommended that you segregate the network traffic bet ween the failover cluster and the virtual
machines.
 The MES objects recovered and managed to reestablish connectivity with the MES Middleware
server on the remote node and resumed normal operational rhythm.
 The following repres entative log entries indicate communication issues observed after the failover
and before the objects recovered:
o Data cannot be read from the MES Middleware, the communications to the MES Middleware
could be brok en.
o Proxy failed to connect to Middleware server service endpoint.
o Counter: JobPos0.Prod.Bad1 encountered an error calling AddProd, error:Proxy failed to
connect to Middleware server service endpoint.

Failover (Triggered by Disconnecting the Host Machine from the

Network)

Applications Scenario RTO (se c) RPO (sec)

MES Service and Middleware server Top of the minute 80 60

MES Service and Middleware server When an Arc hive job is 78 60

in progress

MES Service and Middleware server When a Purge job is in 88 120

progress

Application Server hosting the mac hine shop During normal execution N/A 240
application

Observations
 All jobs were terminated following the Application Server VM failover event and due to the application
design. Full operation required one hour to resume.
 The following log entry was made for each entity indicating communication issues relat ed to the
failover of the Application Server VM:

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LOS T Connection to subscription: [<some GUID>], TableOrView:[ent.getstatusinfobyname] –

Error: The communication object, System.Servic eModel.Channels.ServiceChannel, cannot be
used for communication because it has been Aborted.
 The Archive operation is aborted after the MES middleware failover. This is indicated against the job
in the client and the ArchestrA log on the MES Middleware server. The databas e is not affected.
 The Purge operation is aborted after the MES middleware failover. This is indicated against the job in
the client and the ArchestrA log on the MES Middleware server. The dat abase is not affected.

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