Designing a Cloud-Based MES-SaaS Platform Model in Precision
Machining
YEJI DO1,2, JONGPIL JEONG1*
1Department of Smart Factory Convergence,
Sungkyunkwan University,
2066 Seobu-ro Jangan-gu, Suwon, 16419,
REPUBLIC OF KOREA
2SaaS Research Lab,
Hygino,
25 Simin-daero 248beon-gil, Dongan-gu, Anyang-si, Gyeonggi-do,
REPUBLIC OF KOREA
*Corresponding Author
Abstract: - Smart manufacturing environments are spreading at home and abroad. As a result, SMEs are also
recognizing the need for digital transformation. However, they are facing difficulties in introducing MES/ERP
software due to the initial cost burden and lack of resources. Under these circumstances, this paper aims to
design a cloud-based subscription MES platform that enables SMEs specializing in the precision machining
industry to operate efficient production processes and improve productivity and competitiveness. To build a
cloud-based subscription MES system, we collect and store manufacturing interlocking data based on the AAS
standard and utilize data link sockets such as the EDC standard, which is an important factor in securing
compatibility and integration between various systems. Therefore, we aim to design an MES-SaaS platform that
enables SMEs to utilize MES and ERP software in line with the growth of the smart manufacturing
environment.
Key-Words: - MES, Cloud Platform, SaaS, AAS, OPC-UA, EDC
Received: August 13, 2022. Revised: July 12, 2023. Accepted: August 12, 2023. Published: September 21, 2023.
1 Introduction
A smart factory is a manufacturing execution
system that utilizes cyber-physical systems (CPS)
and digital technologies. It enables the optimization
of the performance of manufacturing areas and the
automatic execution of production processes in real
time to adapt and learn from new conditions, [1].
Smart manufacturing provides insightful
information by collecting and analyzing data from
the manufacturing process. This can be used to
diagnose and improve problems and reduce time to
resolution. It offers the opportunity to increase the
flexibility and productivity of manufacturing
processes and is recognized as a new lean
manufacturing approach that enables data-driven
decision-making and execution.
By implementing a smart factory, many
organizations can realize several benefits. First, by
leveraging sensors, automation systems, and
artificial intelligence technology to monitor and
optimize production processes, they can increase
productivity, reduce costs, and shorten production
cycles. Second, real-time data collection and
analysis can be used to monitor product quality and
proactively detect quality anomalies to reduce scrap
and increase customer satisfaction. Third, you can
achieve sustainable operations through energy
management, resource use optimization, and
environmentally friendly production methods.
In addition, it can increase the reliability of the
system by detecting abnormal conditions or failures
in advance, [2]. Based on these benefits, many
SMEs are adopting smart factories to enhance their
competitiveness. Cloud computing has been
identified by Gartner as a key strategic technology
trend for 2023. The recent COVID-19 pandemic has
increased the demand for remote services and
contactless work. This has increased the demand for
cloud computing in the industry. Companies that
offer cloud computing services provide customers
with a reliable and scalable infrastructure to support
their business operations. These services help to
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improve productivity and efficiency across
industries, [3].
The domestic precision machining industry is
continuously expanding, increasing from 15,641 in
2010 to 21,896 in 2019, and the number of workers
is decreasing, increasing the need and interest in
ICT and digital transformation. SMEs face high
initial costs and lack of resources to build and adopt
software such as MES/ERP (enterprise resource
planning). The lack of compatibility between
MES/ERP solutions from domestic and foreign
manufacturers is driving the need to configure and
utilize modularized systems suitable for each
industry.
In the precision machining industry, the need to
develop industry-wide training and operational
systems through ICT is becoming increasingly
important, and many investments are being made in
the digitalization of the manufacturing environment
to improve efficiency and competitiveness.
For SMEs, we are focusing on the ripple effect in
the economic, industrial, and social sectors and the
ICT sector by applying our specialization in the
precision machining industry and technical expertise
in SaaS cloud-based subscription systems.
Specifically, in the economic, industrial, and social
sectors, the SaaS model has the advantage of
reducing software license costs and server
management costs to increase the economic
efficiency of companies, and it can be applied to
various industries because it is provided in the form
of a platform. The SaaS model also improves
accessibility, making software available to small
businesses and those with smaller budgets, helping
companies develop more sustainable business
models.
This paper is organized as follows Section 2
describes in detail the theoretical background related
to MES, cloud service platforms, AAS, and OPC-
UA. Section 3 proposes the overall system
architecture, hardware and software configuration,
and MES-SaaS security architecture for building an
MES-SaaS system. Section 4 discusses the
limitations of on-premises MES and the challenges
of moving to a subscription service. Section 5
presents conclusions and discusses future research
plans.
2 Problem Formulation
2.1 MES (Manufacturing Execution System)
MES is a system that supports decision-making in
the production department by optimizing production
activities. It manages the production process from
product order to shipment and aims to increase
production efficiency by controlling and managing
production facilities, processes, workers, and
products by collecting and analyzing production site
information in real time.
MES is the system responsible for manufacturing
execution between production automation
equipment and the enterprise-wide system, ERP
(Figure 1). It manages field conditions by
communicating production plans to the field and
monitoring progress. It also performs on-site
integrated management functions that aggregate
performance, collect facility and quality status, and
take necessary measures. Since ERP is a system for
optimally allocating corporate resources and
achieving management goals, business goals are
written into work orders and delivered to the
production site in a top-down manner. Therefore, it
is difficult to understand the process from work
order to production completion. MES, on the other
hand, manages and controls processes and facilities
through real-time data collection and monitoring of
production sites.
Fig. 1: MES System
It also analyzes data accumulated on the
production floor to support production decisions.
This helps to optimize production processes to
shorten delivery times and reduce process rejects.
The Ministry of Trade, Industry and Energy
defines a smart factory as "a factory that maximizes
the overall efficiency of production by combining
advanced manufacturing technologies such as
information technology, software, and 3D printing
in a customized way at the production site."
Therefore, if the purpose of a smart factory is to
improve the overall efficiency of production, MES
is an essential element.
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2.2 Cloud Service Platforms
Fig. 2: Comparative Analysis of IaaS, PaaS, and
SaaS: Part 1
Infrastructure as a service (IaaS) is an evolution
of on-premises infrastructure that provides
virtualized servers, storage, and networks. Server
virtualization technology uses a hypervisor to
partition a single physical server into multiple
virtual servers. Each virtual server is a virtual
machine (VM), which has independent hardware
and behaves like an independent server, [4]. Users
of IaaS services only need to pay for computing
resources based on usage and time, which greatly
reduces the initial investment cost. They also have
full control over virtual machines and other
computing resources, and can easily move existing
applications to the cloud environment, increasing
mobility and interoperability. However, it is
important to be aware of issues such as security
vulnerabilities in existing systems and potential
exposure in the cloud environment, [4].
Platform as a Service (PaaS) provides developers
with a foundation for developing scalable
applications, unlike traditional systems.
Applications in a PaaS cloud environment can be
deployed immediately with flexible control over the
resources and data processing required and can be
gradually scaled to meet usage with no upfront
costs. Although PaaS is a flexible and scalable
service, different PaaS providers offer a variety of
additional services to make program development
more efficient and convenient. As a result,
application services developed in different PaaS
environments are less interoperable, less portable,
and more likely to be vendor-locked. This highlights
the need for PaaS standardization, but it is not
expected to happen because standardizing various
PaaS products means diluting the specialized
features of each PaaS product.
Software as a service (SaaS) is the most
comprehensive form of cloud computing, where the
application software runs on the service provider's
servers. The user sends input data to the cloud via a
web browser and receives the processed results
back. To do this, the communication between the
cloud and the user's web browser is authenticated
and encrypted based on a shared key value. The user
does not need to install or manage any software and
can immediately access the required functionality
via a web browser.
SaaS allows users to use software through a web
browser without installing a separate client program
or going through a complex setup process, [5]. It
also reduces the cost of software deployment and
allows one license to be used on multiple
computers. When providing cloud computing
resources and outsourcing operations, SaaS
providers can provide professional data
management services such as security scans,
backups, disaster recovery, etc. Thus, users are
relieved of the burden of data management and
security. Lastly, a comparative analysis of IaaS,
PaaS, and SaaS: Part 1 and Part 2 are presented in
Figure 2 and Figure 3 respectively.
Fig. 3: Comparative Analysis of IaaS, PaaS, and
SaaS: Part 2
2.3 AAS (Asset Administration Shell)
Germany's Industry 4.0 proposes a complete digital
transformation of manufacturing based on IoT and
CPS technologies, and the reference model RAMI
4.0 has been devised as a concept to realize this, [6].
Fig. 4: RAMI 4.0 Reference Model
RAMI 4.0 is a three-dimensional model that
includes all elements of the three layers (Figure 4).
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On the left-hand side of RAMI 4.0, there is a unified
hierarchy that spans from physical assets to
functions. At the bottom of this hierarchy, "Assets"
includes physical or non-physical assets.
"Integration" refers to the communication of real-
world assets with the virtual world through digital
transformation. 'Communication' refers to the
communication and connectivity between different
assets (e.g. OPC-UA or Open Core Interface).
"Information" means data information on all assets.
"Functional" means the functionality of an Asset.
'Business' means the business part of the Company's
operations. The left horizontal plane of the RAMI
4.0 cross-section shows the life cycle of a product.
There are two product types in RAMI 4.0: finished
products (Instacne) and prototypes (Type). In the
prototype phase, you start with planning, design,
and testing. During this phase, you develop,
maintain, and test the product. In the finished
product stage, production takes place based on a
unique serial number. The rightmost horizontal axis
represents the production automation layer.
Production and Connected World are added to
existing automation standards to show
interoperability between facilities and products.
An AAS, also known as a management shell or
asset management shell, is a virtual, digital
representation of assets to perform interactions
between Industry 4.0 (I4.0) components in Germany
during the Fourth Industrial Revolution. In
manufacturing, assets include not only plant
equipment but also all physical and non-physical
values from order to delivery.
AAS provides and manages all physical asset
information and technical functions in
manufacturing in the information world. The
widespread implementation of AAS in future
manufacturing systems will enable the modularity
and autonomy of systems as production and process
information collected along the manufacturing
process cycle is digitized.
There are several requirements for applying AAS
technology. First, the physical and non-physical
assets of I4.0 components must be uniquely
identifiable (identification), and the related asset
information must be reliable and adequately
described (representation). The AAS shall
communicate with each other, both actively and
passively (Communicate). The AAS should be
operational for a specific period of time based on its
lifecycle (lifecycle phases). The AAS must provide
technical capabilities for asset-specific roles
(capabilities). The AAS must provide a common
sense definition and understanding of asset
information exchanged between assets
(interoperability).
2.4 OPC-UA (Open Platform
Communication Unified Architecture)
OPC-UA is a standard interface recommended by
the Model for Industry 4.0 (RAMI4.0), the
communication layer of the international standard
IEC 62541, [7]. It supports communication within a
single machine, communication between multiple
machines, [8], and horizontal and vertical
communication between machine-to-machine
(M2M) systems, [9]. OPC UA is an essential
technology to ensure interoperability when building
a smart factory. It can freely utilize the data assets
of various devices and facilities that make up a
smart factory. Therefore, it is built on OPC UA for
high-level communication between systems, [7].
OPC UA solves the interoperability problems of
the classic OPC standard by supporting data access
(DA), alarms and events (AE), and historical data
access (HAD) on a single server. The composition
of OPC UA can be divided into an information
model layer that extracts information items related
to equipment and a communication model layer that
delivers the extracted information items.
The composition of OPC UA can be divided into
an information model layer for extracting
information items related to equipment and a
communication model layer for communicating the
extracted information items. The information model
layer provides a way to represent these resources in
the form of computer-readable information to
digitize physical manufacturing resources. The
communication model layer contains standards for
securing communication protocols through data
communication between machines and servers and
servers and clients. The OPC-UA standard
document is presented in Figure 5.
Fig. 5: OPC-UA Standard Document
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2.5 EDC (Eclipse Data Connector)
Current data management environments exist in
many forms, including centralized data management
and distributed data networks, [10]. In general,
centralized data management is when a central
server controls the data and manages and distributes
data from a central system. On the other hand,
unlike centralized data management, distributed data
networks are when data is distributed across
multiple distributed systems or sources. These
systems operate without a unified set of common
rules, which can make it difficult to maintain data
consistency and integrity.
EDC is a Java-based open source software
application supported by the Eclipse Foundation,
[11]. It is used as a tool for connecting
heterogeneous data sources and systems in a
standardized way. EDC enables enterprises to
overcome data consistency and integration issues
that can arise from centralized data management
concepts or distributed data networks, [12]. This
enables organizations to improve data quality and
interoperability.
3 Problem Solution
3.1 MES-SaaS System Architecture
Fig. 6: MES-SaaS System Architecture
In the system architecture presented in Figure 6,
we applied our industrial expertise in precision laser
processing and technical expertise in cloud-based
SaaS systems. In the architecture diagram, the
bottom layer represents sensor data such as
temperature, vibration, pressure, speed, and time
from the UV laser, MSA, and collaborative robot,
which are collected and controlled through the PLC.
The various sensor information collected was
stored according to the AAS standard. To manage
the information assets, we used the AutomationML
AAS standard. This standard provides a basis for
digitizing process assets, integrating them into a
SaaS platform, and collecting data. To integrate and
collect data on the SaaS platform and link data
stored according to the AAS standard, an EDC
standard data link socket is required. The EDC
standard data link socket provides a system that
compensates for the lack of data compatibility
between different information assets and numerous
manufacturers.
In the architecture, Figure 6, the top layer is
designed to store the data collected by the AAS
through the EDC socket to the big database through
OPC-UA, which can be analyzed and utilized in the
MES-SaaS platform. In addition, AAS is built for
each solution of MES on the SaaS platform so that it
can be operated independently without centralized
control.
The solutions built on the SaaS platform include
a bill of materials and inventory system, production
management, material management, business
management, quality management, and condition
monitoring, which are used to manage the main
assets of precision machining manufacturing
companies. In addition, the solution can be
expanded and used if necessary, and functions can
be modified or supplemented. This makes it easy to
integrate and use various solutions through the
MES-SaaS platform.
Finally, as SaaS-based MES platforms are used
by multiple companies, not just one precision
machining manufacturing company, the initial cost
of subscription MES can be lowered, and the
advantage is that the solution can be used
serverlessly without having to build an MES server
locally. In addition, necessary data between
companies can be shared, which can help utilize
resources.
3.2 Hardware Configuration
Fig. 7: Hardware and Software Configuration
The hardware consists of facilities such as UV
laser cutting, MSA, and collaborative robots
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required for precision machining, which are linked
to a PLC for automated control, facility collection,
and monitoring. It also consists of a database to
store data from the existing MES (Figure 7).
In addition, an Edge Gateway, which is
responsible for collecting and storing data from
PLCs, is required to configure a cloud-based MES-
SaaS platform. The Edge Gateway and PLC work in
a client-server manner and require OPC-UA
communication. This provides complementarity by
exchanging data between industrial devices and
systems.
The edge gateway collects data through OPC-UA
communication with the equipment referenced by
the AAS and stores it in a local database in real-time
according to AAS standards. The cloud-based MES-
SaaS platform collects operational data by referring
to the AAS and utilizes it to recognize, install, and
configure equipment. It also constitutes a cloud
environment with enhanced capabilities to process
and analyze the collected data.
3.3 Software Configuration
In terms of software configuration, a traditional
MES system works as a built-in infrastructure
service. The system collects PLC data from existing
production facilities and utilizes it in conjunction
with the MES's database.
Fig. 8: Define the AAS Reference Model of S/W
To collect information stored in your database in
the AAS standard format, you need AAS standard
conversion software. This software consists of a
logical Administration Shell a physical Raw
Database and Asset Module. The Asset Module
contains properties that define the unique
characteristics of information and submodels for
categorizing data. Submodels include Items,
Attributes, From to, etc. This allows non-standard
data to be converted to the AAS standard data
format. The converted data is stored in the AAS
database on the cloud server. The definition of the
AAS Reference Model of S/W is presented in
Figure 8.
The new equipment, which is not present in the
existing system, operates through OPC-UA
communication and collects AAS-based data. To
utilize this collected data, it is first organized into
the AAS standard data format and delivered to the
AASX file and OPC-UA client through the cloud
service. Then, the data is sent through the OPC-UA
Aggregation server on the edge gateway, where it is
organized according to the AAS standard. Finally,
the collected data is stored in the AAS dataset
database on the cloud server in AASX file format.
Through this process, the information assets of
precision machining facilities can be efficiently
operated on a cloud-based MES-SaaS platform and
used to effectively manage and analyze data.
3.4 MES-SaaS Security Architecture
Fig. 9: MES-SaaS Security Architecture
In this study, it was implemented as a SaaS
platform with a multi-tenant architecture to collect
and manage information assets more securely in a
cloud environment. The multi-tenant architecture
works by allowing multiple users to share the same
modules and resources. Each user or tenant is given
a unique ID to access a specific module. This
ensures that data and modules operate in an isolated
boundary so that the data or actions of one tenant do
not affect another. This protects each tenant's
information and increases protection against data
leaks and unauthorized access.
A multitenant environment enables rapid
response to security vulnerabilities by unified
applying security policies and updates across the
platform, maintaining a consistent level of security
across the system, and enhancing prevention and
response to security threats. Additionally, it reduces
costs and improves system efficiency by efficiently
utilizing resources shared by multiple tenants. This
reduces security infrastructure and management
costs and supports efficient operations. In the end, a
multitenant architecture provides consistency and
efficiency in security policies and secures and
protects information assets by separating and
isolating data across tenants and managing security
updates. The MES-SaaS security architecture is
presented in Figure 9.
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4 Conclusion
4.1 Limitations of On-Premises MES
The importance of MES is increasing due to the
rapid growth of smart manufacturing environments.
The global market for smart factories was valued at
$79.41 billion in 2021 and is expected to reach
$191.02 billion by 2030, growing at a CAGR of
10.46%, [13], (Figure 10). This growth highlights
the importance of organizations adopting MES to
efficiently manage their production processes and
improve productivity. MES supports companies'
production processes by providing real-time
information, optimizing production schedules, and
controlling quality, and is recognized as a suitable
solution for smart factories, which are modern
manufacturing environments.
Fig. 10: Global Market Size of Smart Factories
Germany and the United States, both major
manufacturing countries, are pushing hard to
implement smart factories, emphasizing the
convergence of manufacturing and technology. In
particular, SMEs play an important role in the
manufacturing economy, and these countries are
actively supporting SMEs to build smart factories
and have achieved various results, [14].
However, despite its high contribution to GDP,
Korea's manufacturing industry has been relatively
slow to become smart compared to other advanced
manufacturing countries. In addition, since each
manufacturer has its unique operating environment
and requirements, it is difficult for each company to
design and build an MES system due to the high
initial cost and time required.
Traditional MES systems typically have a
hierarchical and centralized structure. This means
that the MES system collects data from multiple
production departments or factories and is
connected to a central server. The central server is
responsible for monitoring the status of the
production process in real-time, managing work
orders, performing quality inspections, etc. The
constraints in establishing smart factories for SMEs
are presented in Figure 11.
Fig. 11: Constraints in Establishing Smart Factories
for SMEs
However, traditional on-premises MES systems
have several challenges. These include costly and
time-consuming custom development and
configuration, lack of available resources, lack of
know-how, solution selection, and lack of
specialized IT departments. It can also be difficult to
update or expand the system, and the typical
centralized structure can limit flexibility and
elasticity. To overcome these constraints, other
approaches are emerging, such as subscription MES
solutions. These approaches break away from the
traditional centralized structure and adopt a cloud-
based or distributed architecture to help you build
and manage a faster, more flexible MES system.
4.2 Issues with Transitioning to
Subscription-based Services
Fig. 12: Global Market Size of Smart Factories
Subscription MES is showing significant growth
at home and abroad. The global market is expected
to grow at a CAGR of 16.3% to reach USD 349.8
billion by 2025, while the domestic market is
expected to grow at a CAGR of 14.9% to reach
KRW 1.14 trillion by 2025 (Figure 12). The cloud-
based subscription MES-SaaS platform is a solution
that solves the problems of traditional on-premise
MES, lowering the cost burden by virtualizing in-
house resources and reducing hardware and
software costs, [15]. In addition, you can enjoy the
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benefits of a flexible system at a reasonable cost as
you can expand or contract the system as needed
and pay only for what you use, and it is provided as
a standard cloud service to minimize the cost of
deployment and maintenance.
However, some issues can arise when switching
to a cloud-based subscription MES. One of them is
data migration and compatibility. This means that
the data accumulated in the existing deployed MES
system must be migrated to the new ME-SaaS. At
this time, issues such as data format, structure, and
compatibility may arise, and careful planning and
transition strategies are required to prevent data loss
or errors. Next, your existing MES system is likely
customized to meet your organization's specific
needs. You'll need to think about how to integrate
and customize these features into your new MES-
SaaS, and if necessary, develop and configure them.
Next up is security and compliance. SMBs are
particularly distrustful of data sharing and use when
adopting the cloud, at 54.4%, which is 13.8% higher
than wait-and-see. This distrust stems from concerns
that data stored in the cloud can be easily shared or
used inappropriately by operators or others. There is
a need to have proper security policies and
compliance measures in place. In addition, the SaaS
model typically requires a monthly or annual
subscription fee, so cost and budget management is
important. Initial investment and operational costs
need to be carefully calculated and managed.
Finally, there are contractual and legal aspects. SaaS
contracts and legal aspects also need to be
considered. Legal commitments, data ownership,
and transfer, contract duration, etc. should be clearly
defined.
By considering these issues and doing enough
planning and preparation before the transition, you
can make the transition from an on-premises MES
to a SaaS-based subscription MES go more
smoothly.
4.3 Conclusion
The main goal of this paper is to implement a
subscription MES-SaaS platform instead of an on-
premises MES system. This will provide better
accessibility, cost savings, ease of maintenance,
ease of updates, scalability, and reliability for
SMEs.
In addition, by converting sensor information and
other informatization assets linked to PLCs in
precision machining facilities into digital
information based on the international standard
AAS, interoperability, operability, continuity, and
economy in data exchange with other solutions,
companies, and countries can be achieved. By doing
so, we aim to help manufacturing companies more
smoothly transition their data assets to a
subscription MES-SaaS platform.
Currently, we are mainly focusing on the design
and implementation of MES-SaaS platform services
for precision machining processes, but in the future,
we plan to complement the solution for collecting
and storing information assets by interlocking with
the AAS base so that SMEs in other industries such
as transportation parts equipment and bio-natural
products can also utilize it. Through this, we will
provide the systems required by various industries
in the form of modules so that each manufacturer
can select the functions they need and use them
easily.
The future platform will establish a value-chain
SaaS ecosystem based on data compatibility,
providing innovative application services to gain a
competitive advantage in a rapidly changing global
business environment. The platform will provide
innovative solutions to small and medium-sized
enterprises in various industries, enabling them to
thrive in the business environment.
Acknowledgement:
This research was supported by the SungKyunKwan
University and the BK21 FOUR(Graduate School
Innovation) funded by the Ministry of
Education(MOE, Korea) and the National Research
Foundation of Korea (NRF).
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Contribution of Individual Authors to the
Creation of a Scientific Article (Ghostwriting
Policy)
The authors equally contributed in the present
research, at all stages from the formulation of the
problem to the final findings and solution.
Sources of Funding for Research Presented in a
Scientific Article or Scientific Article Itself
This research was supported by the SungKyunKwan
University and the BK21 FOUR(Graduate School
Innovation) funded by the Ministry of
Education(MOE, Korea) and the National Research
Foundation of Korea (NRF).
Conflict of Interest
The authors have no conflict of interest to declare.
Creative Commons Attribution License 4.0
(Attribution 4.0 International, CC BY 4.0)
This article is published under the terms of the
Creative Commons Attribution License 4.0
https://creativecommons.org/licenses/by/4.0/deed.en
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WSEAS TRANSACTIONS on COMPUTER RESEARCH
DOI: 10.37394/232018.2023.11.27
Yeji Do, Jongpil Jeong
E-ISSN: 2415-1521
302
Volume 11, 2023