manufacturing operation management
TRANSCRIPT
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Manufacturing Operations Manufacturing Operations ManagementManagement
Manufacturing Operations Manufacturing Operations ManagementManagement
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ObjectivesObjectives
• Review the ISA 95 standards and how they are being used in companies like Eli Lilly & Company for shop floor to top floor integration– The standards provide a formal model for exchanged data
between business systems and manufacturing systems– The models also include a definition of Manufacturing
Operations Management, the activities on the shop floor that take production schedules and perform the actual work required to manufacture products
• The Manufacturing Operations Management models are currently being used in the development of multiple new manufacturing facilities
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Manufacturing in the Supply ChainManufacturing in the Supply Chain
• “Make” is a significant part of the supply chain and collaborative manufacturing, but is often the last element to be actually integrated – Collaboration in “Make” is usually not a “Low Hanging Fruit” – But can offer very high ROI for high volume, or high cost
products
• However, Business IT and Manufacturing IT organizations are often at odds as they try to collaborate– They have different goals and different success criteria– They use the same terms for different elements and different
terms for the same elements
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Collaborative Manufacturing HelpCollaborative Manufacturing Help
• Fortunately there are multiple standards in place to help integrating business systems with manufacturing systems. – The ISA 95 Enterprise/Control System Integration
standards, also an IEC/ISO standard– XML Schemas standards for collaborative
manufacturing from the World Batch Forum
• Will show how they are being applied to the development of manufacturing systems roadmap
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Different Points of ViewDifferent Points of View
• Business Systems – Time Horizons
• Long-term view
– Model detail• Linear route structures
– Control emphasis• Product cost and overall
profitability
– Modeling criteria:• Accounting reference
points• Has inventory value
changed significantly? If not, don’t model separately
– View from the boardroom
• Manufacturing Systems– Time Horizons
• Real-time view
– Model detail• Complex routes with
rework paths
– Control emphasis• Physical movement &
accountability
– Modeling criteria:• material movement
reference points• Does product stop
moving? If not, don’t model separately
– View from the workcenter
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Philosophical OrientationPhilosophical Orientation
• Enterprise Management systems:
–How much is my stuff worth?
• Manufacturing Operations Systems:
–Where is my stuff?
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ISA 95 Provides DirectionISA 95 Provides Direction
• The ANSI/ISA 95.00.01 “Enterprise - Control System Integration - Part 1: Models and Terminology”– Also Draft International Standard ISO/IEC 62264-1
• ANSI/ISA 95.00.02 “Enterprise - Control System Integration - Part 2: Object Attributes”
• Draft ISA 95.00.03 “Enterprise - Control System Integration - Part 3: Activity Models of Manufacturing Operations Management”
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Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc
Manufacturing Operations & Control
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
BatchControl
DiscreteControl
ContinuousControl
Level 4
Level 3
Levels2,1,0
ISA95.01 LevelsISA95.01 Levels
Interface addressedin the ISA 95.01 andISA 95.02 standard
Area addressedin the ISA 95.03standard
Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc
Manufacturing Operations & Control
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
Business Logistics Management (ERP)
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Interface addressedin the ISA 95.01 andISA 95.02 standard
Area addressedin the ISA 95.03standard
BatchControl
DiscreteControl
ContinuousControl
Level 4
Level 3
Levels2,1,0
ISA95.01 LevelsISA95.01 Levels
Manufacturing Operations Management (MES)
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ISA 95 Part 1 and Part 2 ISA 95 Part 1 and Part 2 Exchanged InformationExchanged Information
Information that crosses the boundary between business systems and manufacturing systems
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Exchanged Information CategoriesExchanged Information Categories
Enterprise InformationPlant Production Scheduling,Operational Management, etc
ManufacturingControl Information
Area Supervision, Production Planning, Reliability, Assurance, etc
ProductDefinition
Information(How to make
a product)
ProductionCapability
Information(What isavailablefor use)
ProductionSchedule
(What tomake and
use)
ProductionPerformance
(What wasmade and
used)
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4x4 Object Models4x4 Object Models
• Four categories of resources– Personnel– Equipment– Material (and Energy)– Process Segments
• Four Process, Product, & Production Models – Capability & Capacity Definition– Product Definition – Production Schedule– Production Performance
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Four Resource Object ModelsFour Resource Object Models
People
Materials
Equipment
Personnel resources managed for production
Equipment resources managed for production
Material resources managed for production
Process Segments
Business view of production processes
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Capability, Product, Schedule, and Capability, Product, Schedule, and Performance InformationPerformance Information
ProductDefinitions
ProductionSchedule
ProductionPerformance
What is available for use for production
What is needed to make a product
What to make and resources to use
What was made and resources actually used
Product
Time
Capability/Capacity
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Production ScheduleProduction Schedule
People
Materials
Equipment
Segments
ProductionSchedule
What to makeWhat to make- Priority and/or datesPriority and/or dates- What materials to useWhat materials to use- What equipment to useWhat equipment to use- What personnel to useWhat personnel to use- Production parameters Production parameters (e.g. Color, Options,…) (e.g. Color, Options,…)
Per location (Site, Area, …)Per week, day, shift, order, …
• Production ScheduleProduction Schedule• Production RequestProduction Request• Segment RequestSegment Request
• Expected Produced MaterialExpected Produced Material• Expected Consumed MaterialExpected Consumed Material• Expected PersonnelExpected Personnel• Expected EquipmentExpected Equipment• Production ParametersProduction Parameters• ……
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Production Performance Production Performance
People
Materials
Equipment
SegmentsProduction
Performance
What was madeWhat was made- What material was What material was actually produced actually produced- What materials were What materials were actually consumed actually consumed- Equipment usedEquipment used- Personnel usedPersonnel used- Production dataProduction data (e.g. Purity, density,…) (e.g. Purity, density,…)
Per location (Site, Area, …)Per location (Site, Area, …)Per shift, hour, Per shift, hour, end of batch, …end of batch, …
• Production PerformanceProduction Performance• Production ResponseProduction Response• Segment ResponseSegment Response
• Produced Material ActualProduced Material Actual• Consumed Material ActualConsumed Material Actual• Personnel ActualPersonnel Actual• Equipment ActualEquipment Actual• Production DataProduction Data• ……
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XML Standard for B2M ExchangesXML Standard for B2M Exchanges
• The World Batch Forum has developed XML Schemas that map to the ANSI/ISA-95 models
• Defines how to represent the ISA-95 information in XML– Business To Manufacturing Markup Language– B2MML
• One schema for each object model• Formal way to exchange information
– www.wbf.org
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<Material<MaterialLot> <ID> W89W89 </ID> <Description> A lot of materialA lot of material </Description> <MaterialDefinitionID> WXE908WXE908 </MaterialDefinitionID> <Location> Tank 1Tank 1 </Location> <Quantity UnitOfMeasure = "KLKL" > 45004500 </Quantity> <MaterialLotProperty>
<ID> dateTimeProductiondateTimeProduction </ID> <Value> 2001-01-06T00:14:23+11:302001-01-06T00:14:23+11:30 </Value>
</MaterialLotProperty> <MaterialLotProperty>
<ID> Quality StatusQuality Status </ID> <Value> GoodGood </Value>
</MaterialLotProperty></MaterialLot>
</Material>
An XML Example – Material LotAn XML Example – Material Lot
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ISA95 Part 3 ISA95 Part 3 Activity Models of Activity Models of Manufacturing OperationsManufacturing Operations
In Development
Expected Release 2004
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INVENTORYOPERATIONS
INVENTORYOPERATIONS
MAINTENANCEOPERATIONS
PRODUCTIONOPERATIONS
QUALITY
ASSURANCEOPERATIONS
Procurement(5.0)
ProductionScheduling
(2.0)
Material andEnergy Control
(4.0)
ProductInventory Control
(7.0)
Product CostAccounting
(8.0)
QualityAssurance
(6.0)
ResearchDevelopment
and Engineering
ProductShipping Admin
(9.0)
OrderProcessing
(1.0)
Marketing& Sales
ProductionControl
(3.0)
MaintenanceManagement
(10.0)
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ISA 95.03 Manufacturing Operations FunctionsISA 95.03 Manufacturing Operations Functions
Productionresource
management
Productioncapability
Analysis
Productiondata
collection
Productionexecution
Productiondispatching
Productiontracking
Productionperformance
Detailedproductionscheduling
Productionschedule
Level 2 Process Control
Productdefinition
management
Productdefinition
Equipment and ProcessSpecific Production Rules
Equipment and ProcessSpecific Data
OperationalResponses
OperationalCommands
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MajorActivities
WithinManufacturing
Operations
QualityOperations
MaintenanceOperations
ProductionOperations
Level 4
Level 3
Level 2
Management of Configuration
Management of Information
Management of Security
Management of Documentation
Management of Compliance
InventoryOperations
Other Enterprise Activities in Other Enterprise Activities in Manufacturing OperationsManufacturing Operations
• Some actives are not specific to manufacturing• ISA-95.03 lists references to standards in these
areas
Activity detailed
Activity not detailedActivity outside scope
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ImplementationsImplementations
• Nestle– Project to use the XML schemas for schedule
exchange
• Arla Foods– Project to use XML for standard interfaces to
multiple ERP systems and MES systems
• Empersas Polar– Project to use XML schemas for schedule
exchange
• Eli Lilly– Projects to use ISA 95 models for manufacturing
operations management architecture
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Building Collaborative Manufacturing Building Collaborative Manufacturing SystemsSystems
• Process Used to Develop Solution Architectures– Conceptual Topology– Functional Areas– Standards and Guidelines – Standard Applications– Logical Architecture Design– Physical Architecture Design
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ISA 95 Control Hierarchy LevelsISA 95 Control Hierarchy Levels
Level 4
Level 0
Level 1
Level 2
Level 3
Business LogisticsPlant Production Scheduling, Shipping,
Receiving, Inventory, etc
ManufacturingOperations Management
Dispatching, Detailed ProductionScheduling, Production Tracking, ...
BatchProduction
Control
DiscreteProduction
Control
ContinuousProduction
Control
ISA – IEC/ISO InterfaceStandards
IEC, OPC, & OMAC InterfaceStandards
ISA FunctionalModel
The production processes
What is the PCIMS ?
PCIMS :Process Control Information Management System
Each plant as an individual process area shall consist of an integrated production control system and the main units of integrated production system consist of :
UCB : Unit Control Building which is the central location for controlling , PCB: process control building
RIB which houses all I/O’s and the controllers
DCS is Distribution Control System
Vendor ,Yokogawa centum CS3000
DCS consist of two main parts :
HIS : Human Interface Station
FCS : Field Control Station
- it is operator station that is used to monitor and control the process .
FCS is a stand alone unite capable of performing a full data acquisition control ,and all control function are executed there with all I/O’s analog & digital signal.
What is the DCS ?
What is the PESS ?
PESS : Programmable electronic safety system Vendor : ( Triconex )
which is used for emergency shutdown (ESD) function and other equipment tripping function .
What is MMS ?
MMS : Machine Monitoring system Vendor : ( Bentlt Nevada )
Machine Motoring System , the Bently Nevada system is used to monitor the vibration of the shaft and the baring shaft temperature , and to send a signal as hard wire to the shut down system “ PESS” to trip the machine . Which is used in Comp package & critical big Pump..etc.
Like :Tank gauging ,Flow computer for custody meter and Vibration monitoring “ System 1”
Third party Equipment
What is RIB ?
RIB is Remote Instrument Building
The Remote Instrument Building RIB, which will house, the DCS controller as FCS ,HIS ,PESS / PLC controller and their cabinets and all other 3rd party equipment like Tank gauging ,Vibration monitoring , Flow computer , Power supply distribution panel ,Fire and Gas panel and Uninterruptible power supplies (UPS ) .
- DCS filed control station “ FCS “ Cabinets
- Programmable electronic shut down system “PESS Cabinets
- Machine monitoring system “ MMS Cabinets
- Programmable logic control “PLC” Cabinets
- Other equipment such as Tank Gauging , Custody metering Cabinets
- Air unit
- Fire and gas panel
- All field instruments , wiring signals
- Marshaling panels
-Terminal blocks
-Servers cabinets
What is inside RIB’s
JB
F TA
HIS
TB
FCU
FIO
HIS HIS HIS
Control Room
V-net cable 10 base 5
Optical converter
Fiber optic cable
V-net cable 10 base 2
coaxial cable
RIB
FCSB/N TMR
PLC
Copper multi coreshielded cable
FTA or I/O's cabletwisted multi core ,as TEL cable
One pair copper cable
Serial communication link
Hard wire
YNT
FOPP
YNT
FOPP
V-net converter 10 base 5 to 10 base 10
Black box
To do down loading , Tag equalizing between the HIS,s,Trending , and viewing DCS logic
DCS OPC server
V-net 10 Base 2 cable
Control room YNT
V-Net 10 Base 5 cable
Fiber optic cable
RIB YNT
V-Net cable 10 base 5
FIO
FCS
HIS
RIB Control Room
Fiber optic 100 MP/S
Fiber optic 1GP/S
2
copper
Fiber
PLC, PESS
PESS – PLC OPC server
DCS OPC server
One jacket fiber optic cable consist of 6 orange cable which consist of 4 wire
The total is 12 pare wire inside one jacket
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ConclusionsConclusions
• Linked execution systems deliver results!– Reduced direct costs; increased productivity– Improved traceability; reduced “witch hunt” expense– Near-theoretical cycle times: customer responsiveness,
reduced WIP inventory– Greater agility: smaller lot sizes, more premium products in
the mix, happier customers, happier shareholders!
• S95 defines the currency for manufacturing object and information exchange– Faster project implementation cycles– Flexibility to integrate and realign as corporate structures
change
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StatusStatus
• ISA95.00.01 & ISA.95.00.02 available• IEC/ISO 62264-1 available from IEC & ISO• ISA 95.00.03 in draft
– Still under development in the committee
• World Batch Forum– Developed XML Schemas for the exchanged
information
• Vendors– Many currently using ISA-95 models in
development and current products
• Users– Specifying ISA-95 in their RFPs