s95 tutorial
TRANSCRIPT
1Dennis Brandl
Manufacturing OperationsManagementManufacturing OperationsManufacturing OperationsManagementManagement
Dennis Brandl Peter OwenBR&L Consulting Eli Lilly & Co
2Dennis Brandl & Peter Owen
ObjectivesObjectives
• Review the ISA 95 standards and how they are beingused in companies like Eli Lilly & Company for shopfloor to top floor integration– The standards provide a formal model for exchanged data
between business systems and manufacturing systems– The models provide a definition of Manufacturing Operations
Management, the activities on the shop floor that takeproduction schedules and perform the actual work requiredto manufacture products and provide visibility of production
• The Manufacturing Operations Management modelsare currently being used in the development ofmultiple 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 andcollaborative manufacturing, but is often the lastelement 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 ITorganizations are often at odds as they try tocollaborate– 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 inplace to help integrating business systemswith 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 systemsroadmap
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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 overallprofitability
– Modeling criteria:• Accounting reference
points• Has inventory value
changed significantly? Ifnot, don’t modelseparately
– View from the boardroom
• Manufacturing Systems– Time Horizons
• Real-time view– Model detail
• Complex routes withrework paths
– Control emphasis• Physical movement &
accountability– Modeling criteria:
• material movementreference points
• Does product stopmoving? If not, don’tmodel separately
– View from the workcenter
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Philosophical OrientationPhilosophical Orientation
• Enterprise Management systems:– How much is my stuff worth?– How much stuff do I have/need?
• Manufacturing Operations Systems:– How do I make my stuff?– Where is my stuff?
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ISA 95 Provides DirectionISA 95 Provides Direction
• The ANSI/ISA 95.00.01 “Enterprise - ControlSystem Integration - Part 1: Models andTerminology”– Also Draft International Standard ISO/IEC 62264-1
• ANSI/ISA 95.00.02 “Enterprise - ControlSystem Integration - Part 2: Object Attributes”
• Draft ISA 95.00.03 “Enterprise - ControlSystem Integration - Part 3: Activity Models ofManufacturing Operations Management”
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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
The production processes
Interface addressedin the ISA 95.01 andISA 95.02 standard
Area addressedin the ISA 95.03standard
9Dennis Brandl & Peter Owen
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
The production processes
Interface addressedin the ISA 95.01 andISA 95.02 standard
Area addressedin the ISA 95.03standard
ManufacturingOperations Management
(MES, LIMS, AM, …)
Business LogisticsManagement
(ERP)
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ISA 95 Part 1 and Part 2ISA 95 Part 1 and Part 2Exchanged InformationExchanged Information
Information that crosses the boundary betweenbusiness 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, andCapability, Product, Schedule, andPerformance 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
ProductTime
Capability/Capacity
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Production ScheduleProduction Schedule
People
Materials
Equipment
Segments
ProductionSchedule
What to makeWhat to make-- Priority and/or dates Priority and/or dates-- What materials to use What materials to use-- What equipment to use What equipment to use-- What personnel to use What 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 PerformanceProduction Performance
People
Materials
Equipment
Segments ProductionPerformance
What was madeWhat was made-- What material was What material was actually producedactually produced-- What materials were What materials were actually consumed actually consumed-- Equipment used Equipment used-- Personnel used Personnel used-- Production data Production 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 XMLSchemas that map to the ANSI/ISA-95models
• Defines how to represent the ISA-95information in XML– Business To Manufacturing Markup Language– B2MML V2.0
• 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 3ISA95 Part 3Activity Models ofActivity Models ofManufacturing OperationsManufacturing Operations
In DevelopmentExpected Release 2004
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INVENTORYOPERATIONS
INVENTORYOPERATIONS
MAINTENANCEOPERATIONS
PRODUCTIONOPERATIONS
QUALITYASSURANCEOPERATIONS
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 OperationsISA 95.03 Manufacturing OperationsFunctionsFunctions
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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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 inOther Enterprise Activities inManufacturing OperationsManufacturing Operations
• Production, Maintenance, Inventory, Quality• Management of information, compliance, security,
documentation, and configurations
Activity detailed
Activity not detailed
Activity 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 tomultiple ERP systems and MES systems
• Empersas Polar– Project to use XML schemas for schedule
exchange• Eli Lilly
– Projects to use ISA 95 models for manufacturingoperations management architecture
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Building Collaborative ManufacturingBuilding Collaborative ManufacturingSystemsSystems• Process Used to Develop Solution
Architectures– Conceptual Topology– Functional Areas– Standards and Guidelines– Standard Applications– Logical Architecture Design– Physical Architecture Design
25Dennis Brandl & Peter Owen
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/ISOInterfaceStandards
IEC, OPC, &OMACInterfaceStandards
ISAFunctionalModel
The production processes
26Dennis Brandl & Peter Owen
Conceptual Topology – IT ViewConceptual Topology – IT View
• IT View of the ISA-95 Levels and relationship tosystems and networks
• Levels 1-2– Control the process and provide visibility to the process– Electronic records are not embedded in the control layers
(Level 1-2)– Usually some specialized hardware and possibly networks
• Level 3– Maintenance of production information is centralized to
provide greater control and availability of the records– Electronic records are managed and controlled through
Level 3 systems with audit trail, access control, backup, andERP connectivity
– Usually standard hardware and networks
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Conceptual Topology – IT ViewConceptual Topology – IT View
Level 4
Level 1
Level 2
Level 3
I/O, Devices,Sensors
ERP, APO,Logistics Systems
MES, LIMS, WMS,CMM Systems
PLC, DCS, Packaged Systems
Business Process Information Network
Operations Information Networks
Automation Networks
Discrete & Process Device Communication Networks
HMI, SCADA,Batch Systems
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Functional AreasFunctional Areas
• Use the ISA 95 and ISA 88 models of functions• Map the functions to system areas and networks• Use the ISA 95 rules for determining what is in Level
3 (vs Level 4)– The function is critical to plant safety– The function is critical to product quality– The function is critical to plant reliability– The function is critical to maintaining regulatory compliance.
• Includes such factors as safety, cGMP, and environmentalcompliance
• Maintaining FDA, EPA, USDA, OSHA, TÜV, EU, EMEA, andother agency compliance
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Level 1
Level 2
Level 3
Business Process Information Network
Operations Information Networks
Automation Networks
Discrete & Process Device Communication Networks
Functional Areas – From ISA 95 & 88Functional Areas – From ISA 95 & 88
Phase Control
Operator Visibility
Sense Process
Manipulate Process
Sense Events
Manipulate Equipment
On/Off Control Continuous Control
Interlock & Safety Control
Equipment Information Collection Recipe Control
Product Definition Management
Resource Management
Net
wor
king
Net
wor
king
Net
wor
king
Operator ControlAlarm Management
Programmed Control
Supervisory Control
Net
wor
king
Production Dispatching
Production Execution Configuration Management
Production TrackingDetailed Scheduling
Production Analysis
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Logical ArchitectureLogical Architecture
• Maps functional areas and data locations– Independent of technology
• Defines the different layers of the architecture interms of data and control– These are mapped to physical networks, servers, and
applications in the physical architecture• Defines what functions are to be performed at each
level, and what data is to be maintained at each level– To result in maintainable and robust systems– To provide a way to manage the life cycle of the production
systems– Provides the structure required to grow and modify the
system without compromising any of the previousadvantages
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Level 1Level 1
Level 2Level 2
Level 3Level 3
Logical Architecture – IT ViewLogical Architecture – IT View
Process/EquipmentSensors/Actuators
ControllersProd
uctio
n A
reas
Operations Information Network
Cen
tral
ized
Serv
ers
Des
ktop
Automation Network
Device Connection & /Networks
Business Information Network
Supervisory HMI
Reporting HMIInvestigations, Trends, …
Packaged Equipment
Fault tolerant Site Data StorageMES
Data Acquisition
Engineering ToolsDiagnostics, analysis, …
Operator ControlBatch Execution
Real-time Data andBufferingReal-time
Control and DataCollection
Permanent DatabaseOperations Control
Reports andAnalysis
Recipe Execution
Area Data StorageERP Connection
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A Physical ArchitectureA Physical Architecture
• Defines the IT infrastructure and applications– Defines networks and network connections– Defines locations of applications– Defines locations of servers– Defines the mapping of applications to servers
• Physical architecture depends on the solutionset used:– Vendor capabilities– Networks– Security and network management– …
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Level 3
Physical Architecture – IT ViewPhysical Architecture – IT View
Level 1
Level 2One Instance PerProcess CellAutomation Networks
Area Operations Information Networks
Ethernet
Ethernet
High AlarmLow AlarmComm. Err.HMI
Viewer
Packaged EquipPLC
SiteInformation
NetworkVLANSwitch
ERPConnection
VLANSwitch
2 way Firewall
DNSDomain Ctrl
DCS
XML
NetworkNetworkManagementManagement
RouterRouter
NetworkNetworkManagementManagement
RouterRouter
NetworkNetworkManagementManagement
RouterRouter
DNSDomain CtrlHistorian
Reporter
ConfigurationServer
MESServer
Gateway
HistorianCollection
HMI Server
OPC
DataBaseServers
Embedded PC
Ethernet
Ethe
rnet
BatchExecution
WMSExecution
Device Networks
High AlarmLow AlarmComm. Err.Eng Tools
Diag Tools
Non operations toolsand views into data
One Instance Per Site
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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
35Dennis Brandl & Peter Owen
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 exchangedinformation
• Vendors– Many currently using ISA-95 models in
development and current products• Users
– Specifying ISA-95 in their RFPs