industrial it system 800xa isa-95/s88 standards batch information management mes functionality

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Industrial ITSystem 800xAISA-95/S88 StandardsBatchInformation Management MESfunctionality

Arto Lind

13 mars 2007

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ISA-95 Perspective on Manufacturing

Business Planning & Supply Chain

MgmtBusiness Process

transactions

Manufacturing Operations Management

ISA-95.01/02Definition

Production Definition

Production Capability

Production Plan

Production Information

Production Production Management Management TransactionsTransactions

Real-Time Control & Real-Time Control & EventsEvents

BatchBatchContinuous DiscreteDiscrete

ISA-95.03/04 Functionality

Level 0, 1, 2Level 0, 1, 2

Man

ufa

ctu

rin

g F

acil

ity

TTP

F

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F

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F

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TTP

F

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L

F

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TTP

F

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Sensors, Actuators and Logical Devices

ISA-95.05Functionality

Timeframe: Months, weeks, days, shifts

Timeframe: Day, Shift, Hour, Minutes, Seconds

Level 3

Level 4

ABB Coverage

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ISA S95 Standard Scope

SITE

AREA AREA AREA

CONTINUOUSPRODUCTION

UNIT

DISCRETEPRODUCTION

LINE

ISA95Standard

ENTERPRISE

95.0395.03

95.01 & .0295.01 & .02

BATCHPROCESS

CELL

ISA S88Standard

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Enterprise and Control Layers are Merging

Enterprise Layer

Control Layer

CPM Layer*

(if existing)

1995

Extended ERP

De

tail

ed

Pro

du

cti

on

S

ch

ed

uli

ng

Pro

du

cti

on

Re

so

urc

e

Ma

na

ge

me

nt

Pro

du

ct

Da

ta

Ma

na

ge

me

nt

Pro

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cti

on

Da

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lle

cti

on

Pro

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ct

An

aly

sis

Ma

inte

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nc

e

ma

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ge

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nt

Pro

du

ct

tra

ck

ing

Pro

du

cti

on

a

na

lys

is

Extended Manufacturing

2005

Plant Instrumentation and Controls

Business Planning & Logistics Production Planning

ERP

DCS / PLC

SCADA

Manufacturing OperationsExecution and Control

MES

1985

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Platform for Control and CPM/MES One common platform for all manufacturing functions

Utilize modular 800xA software functions as required

Batch Management

Manufacturing Management

AssetOptimization

Common Operations, Engineering, & Data Management

Enterprise Connectivity Solutions (ECS)

Blending Granulation Tablet Coating Other OPC

Information Management

Real-Time Production Intelligence

- - - - - - - - - - - - - - - - Real-time Data Sources- - - - - - - - - - - - -


Web ServicesWeb Services

ISA-95

Specific AdaptorsSpecific Adaptors

ERP

Traditional InterfaceTraditional Interface

LIMS/DMS/etc

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Scope of ISA 95 Part 3

To Define:

Activities of manufacturing Operations Management

Terminology and a consistent set of concepts and models for defining manufacturing operation management activities

Interactions between activities

Data that flows among these activities

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Production Operations

Productiondata

collection

Productionexecution

Productionresource

management

Productiondispatching

Productiontracking

Productionperformance

Detailedproductionscheduling

Productionschedule

Productdefinition

management

Production level 1-2 functions

ProductionPerformance

analysis

Productioncapability

Productdefinition

Equipment and processspecific production rules

Equipment and processspecific data

Operationalresponses

Operationalcommands

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ISA S95.03d Production Control Functions

ProductionCapability

ResourceManagement

HistoricalData

Management

ProductionExecution

ProductionDispatching

ProductionTracking


DetailedProductionScheduling

ProductionSchedule

ProcessAnalysis

ProductionAnalysis

(QA) ProductAnalysis

ProductDefinition

Management

ProductDefinitions

AutomatedControl

ProcessMonitoring

ManualOperations

800xA Production Management

-Batch

800xA Information Management

800xA Operations

Supply ChainIntegration

ECS – EnterpriseConnectivity Solution

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Batch Management is a comprehensive batch automation solution for:

Configuring recipes and procedures

Configuring batch equipment

Scheduling, monitoring and controlling batches and campaigns

Automatic arbitration of resources between batches at runtime

Collecting and storing batch historical information

What is 800xA Batch Management?System 800xA

Production Management

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ISA S88.01 Batch Standard

Procedure HierarchyProcedure HierarchyEquipment HierarchyEquipment Hierarchy

Area

Process Cell

Unit

Equipment Module

Procedure

Unit Procedure

Operation

PhaseWhatWhat

HowHow

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ISA S88 Procedure Hierarchy Production strategy organized by levels

Procedural elements can be used in multiple procedures

An element within a Procedure Function Chart (PFC) may represent another nested Procedure

InertInertUnit ready

Press > target

InitializeInitialize

Pressure

VentVent

ProcedureProcedure

Unit Unit ProcedureProcedure

PhasePhase

OperationOperation

An element within a PFC may launch and supervise sequential logic in process controller

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Product Definition Management

Procedure Function Chart (PFC) Editor provides a graphical workflow of operations and procedures

System 800xAProduction Management

Single master recipe for automated and manual production workflows

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Integrated Equipment Configuration

Supports network, multi-path and single path equipment configurations

Integrates with the common object model of 800xA System

Reserves and allocates equipment and other resources at run-time based on priority of each batch

Provides views and control of equipment status (Available, Busy, Reserved, etc.), Batch ID, equipment attributes, and reservation queue Single, unified plant object model

reduces engineering costs.

System 800xABatch Management

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Production Resource Management

View equipment status (Available, Busy, Reserved, etc.)

View Batch ID

View and change equipment attributes

View and manipulate reservation queue


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Production Scheduling / Dispatching

Schedule control recipes based on master recipes and batch-specific formulation data

Supports multiple execution of batches within a campaign

Select equipment at schedule time or dynamically at run-time

View batch status, parameters, history options and messages

Easily navigate procedure hierarchy of all active batches

One-button duplicate feature

Simple utilities for Recipe, Resource, and Production Management

provide full functionality.


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Production Schedule Interface

Enables interfaces from 800xA to external applications

Examples of actions supported Scheduling a batch

Retrieving status information

Changing batch state and parameters

Retrieving batch history variables

Provides complete access to information required for business system integration.

System 800xAProduction

Management

Batch Management

Manufacturing Management

Create Process

Order

Business System

Execute Process

Order

Upload Process

Order

System 800xABusiness System

ScheduleBatches

ProductionRecords

ProductionResponse(s)

ProductionRequest(s)

* ** Message broker / Transaction Mgr

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Functional Structure and Components

Engineering Production(68)

RCM(62)

DDRIVE(123)AO (29)

(68)

AO (29)

Control Recipes

Scheduler

Plant Explorer

Control & I/O

Operations

Batch Management

Server

InformationManagement

PDL

Production Orders

Production Orders Production

Reports

Production Reports

Control ProceduresBatch EventsOperator Comments

Numeric Trend DataControl & System EventsOperator Actions

ERP/MES Applications

Phases

Recipes

Operations


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Common Equipment Model of System 800xA

Unit TypesInstances of

Physical Equipment

MasterRecipes

EquipmentGroups

ProcedureStructure

EquipmentStructure

FunctionalStructure

Object TypeStructure

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AC800M Controller Integration

Equipment Procedure Template (EPT) Phase Logic Interface to Produce IT Batch

Separate code blocks for S88 states (e.g. running, holding, aborting, etc.)

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Operator Workplace with Batch

Equipment Overview

Process Graphic

Procedure Function

Chart

Batch Overview


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Flexible Recipe Management

Reusable recipe building blocks follow S88 batch control standard

Exception procedures provide recipe-driven error handling capability, breakpoints and block skip points

View current status of recipe procedures and associated standard operating procedure

Supports on-line changes to control recipe without suspending the batch

Improves production yields, minimizes scrap, and improves overall production profitability.

Procedure Function Chart Standard Operating

Procedure


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Full Support for FDA 21 CFR Part 11 System 800xA provides features across the

entire system that facilitate validation

Security – authorization & access control

Configuration change management

Versioning

Synchronization between engineering & production systems

Batch will provide on-line versions for procedures

Audit trail – logging by audit event type

E-signatures & signature/record linking

Record archiving & retrieval

Reporting - printed copy of records for inspection

System checks - device checks and permitted sequences

Native language support

SOPs for Part 11 and cGMP

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Batch Production Data Management

Logs batches according to procedure hierarchy

Displays and analyzes trends of same or different batches

Supports LAB data entry

Prints reports using third party report builder

Archives data and reports

Provides access to other applications through SQL and programmed APIs The hierarchical data storage greatly

facilitates batch to batch analysis quickly providing useful information for making

intelligent business decisions.

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ResourceManagement

HistoricalData

Management

ProductionExecution


ProductionTracking



ProductionSchedule

ProcessAnalysis

ProductionAnalysis


ProductDefinition

Management

ProductDefinitions

AutomatedControl

ProcessMonitoring

ManualOperations


-Batch


800xA Operations



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Desktop, Reporting & Analysis

Production Performance Analyses - Information Management

Process Data Alarm & Event Data Production Data

Control Room

Application Integration

ExternalProduction

Data(ERP, MES etc..)Archiving Engine

Data

Informationavailability


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InformIT Information Manager Architecture

Information ManagerEnterprise Edition

Server

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Control Network

Seamless handling of historical data

Messages in the

800xA System

50k messages50k messages

1 sec /1 week1 sec /1 week

50k messages50k messages – – 12 million messages12 million messages

- 1sec / 10 years- 1sec / 10 years

1 sec /1 week1 sec /1 week

Trend logs in Connectivity

Server

Systemalarms/events

Audit Trail alarms/events

Process alarms/events

Real-time and History data

in History Server

Seamless view of all data

Archive

Operator Workplace/Desktop Display

Historical storage

OPC Data Access items: 40.000 itemsOPC update rate: > 0.1s (1s default)Primary logs/Con.Server: 5.000 logsPrimary logs/IM Hist.Server: 30.000 logs Updated min log values: 30.000/minReq. max buffer size: Con.Server: 3 months Max buffer size: IM Hist.Server: 10 years


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Production Data Log

Robust data structures Correlation of batch history with continuous history (highly configurable -- doesn’t require custom code) Batch to Batch comparisons Pre-canned reports that can be used “right out of the box”

B

Batch 19/29/95 14:05:009/29/95 22:07:25

Job Name:Recipe Name:

Production Polystyrene grade 4Polystyrene_A4

Batch Name:Start T ime:End T ime:

Unit Procedure:Unitname:Start time:End time:

ReactionReactor R-1059/29/95 14:30:209/29/95 18:23:03

Phasename:start:initial temp:target temp:end:final temp:

Heat9/29/95 14:32:4023.5 Deg. C55.0 Deg. C9/29/95 16:35:1255.1 Deg. C

Batch 1

UnitProceedure 1

Operation

Batch 2

Campaign

Batch 1

UnitProceedure 1

B atch 2


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Presentation and Navigation

Seamless process and history data retrieval Straightforward trend presentation Process Portal Trend Display and Information Manager Display

Clients present common (short and long term) set of data Plant Explorer navigation for Information Manager data


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Presentation and Navigation

Single, seamless interface for accessing and viewing all data in the system

Maintain data in original control system format Process alarms, system events, operator actions

Production data, process relationships


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Web ClientsInformation Management

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DeskTop Trend Trend Control

Tag Ticker

Presentation and NavigationInformation Management

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Softpoints & Calculation exempel

Softpoint object

Softpoint signals

Calculation aspect

Calculation script

User-defined data pointsTransform data into

actionable information

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Flexible Report generation & distribution

Microsoft Excel, Crystal Report

Real time data, historical, lab data, batch- and event-information

Report generation Printer Email Historical archiving Lolal- or network-disc

Flexible Reports

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Secure Data Security in Pharmaceutical Industry

Secure historical data storage Archival/retrieval from external

media CD, DVD, Magneto Optical Remote disk location Direct read of archived tag

data Archive based on production

event such as batch end

Distributed data storage Secure report storage Disk arrays

User access control

Security

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Campaign Name:Recipe Name:

Intermediate_S7_2004AXH Int_S7_Std

Unit Procedure:Unitname:Start time:End time:

ReactionRE1059/12/04 14:30:209/12/04 18:23:03

Operation name:Start time:

Heat9/12/04 14:32:10

Camp1

Batch 1

UP1

OPN 1

Batch 2

End time: 9/12/04 17:32:40

Batch_19/12/04 14:05:00

Batch Name:Start Time:End Time: 9/12/04 22:07:00

Production Data Collection / Tracking

Single common storage of batch record

Data stored according to batch recipe structure

All batch events, operator actions, system events, process alarms and events are stored

System 800xAInformation

Management

Complete electronic batch records

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ResourceManagement

HistoricalData

Management

ProductionExecution


ProductionTracking



ProductionSchedule

ProcessAnalysis

ProductionAnalysis


ProductDefinition

Management

ProductDefinitions

AutomatedControl

ProcessMonitoring

ManualOperations


-Batch


800xA Operations



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Introduction

ECS

ECS Framework closes information gap between Business processes and the Manufacturing processes (machines, control systems).

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Functionality

BRIDGE BETWEEN PLANT FLOOR CONTROL SYSTEMS AND ENTERPRISE BUSINESS SYSTEMS

ENHANCEMENT OF RESPONSIVENESS TO BUSINESS DECISIONS

MANUFACTURING VISIBILITY - EFFICIENCY ISSUES, PRODUCTIVITY ISSUES, AND QUALITY ISSUES IN CONTEXT

PRODUCTION REALITY – PLAN, RESPOND AND CHANGE ON DEMAND; NO MORE GUESSING

QUALITY DATA MANAGEMENT - RECOGNISE AND RESPOND TO QUALITY CHALLENGES

EVOLUTIONARY APPROACH - CONTINUOUS IMPROVEMENT

ECS =ECS =

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Levels

IT Framework

Manufacturing Framework

Applied Manufacturing Framework

Methodology and tools for modeling and implementation of solutions for different factories and manufacturing

Factory and domain specific deployments

800xA Core Platform

Reusable software components, fully integrated in 800xA Core Platform

domains.

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ECS Based Connectivity

ECS Makes Business Systems visible to the rest of the 800xA System as just another control equipment

800xACore

BusinessSystem

800M Controller

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Manufacturing Process Model Based on S95 standard

Includes Process data

Process workflow definition

Representation of the process model is saved as an XML file

S95 Objects

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Manufacturing Process ExecutionManufacturing Process Modeling tool (S95)

ExecutableCode

BusinessSystem1Business

System1BusinessSystems

Devices

People(GUI)

Model-based Integration

Manufacturing ProcessDatabase

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Download of the SAP control recipe to 800xA System with all parameters required for batch production

800xA system updates SAP system with production status throughout the batch execution

At the end of batch production 800xA system reports to SAP all production relevant data (consumption per ingredient, produced material quantity, Phase confirmation and report of used machine and total production time etc.)

ECS- Enterprise Connection Solution Configurable connectivity to various business systems (e.g. SAP)

or any ERP from SSA Global including BAAN Tracking & Traceability, Reports, Database connector Based on

Case: SAP PPPI – ABB 800xA Batch Management integration

SAPPP-PI

Control System

800xA Batch

ECS800xA IM

BAPIs, RFCs

SAP Control Recipe

Batch production data (consumption, confirmation, quantity produced)

MES

- 95

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Task forceresults withrecommendations

2004-04-12

Development of the ABB-SAP Joint Solution

2004-04

ABB-SAPCo-operationinitiated

20062004-12

Sapphire Paris

Joint solutionready to deploy

2005

Joint solutiondevelopment

ABB-SAPTask forcePulp & Paper

Initial industry: Pulp & PaperTaskforce Charter:

Define appropriate customer segmentation (products, regions,…)

Identify pain points of the different customer groups

Determine where there are pain points which are significant and where we can find/have a combined solution

Identify value proposition (quantifiable) for Customer ABB SAP

Define possible integration scenarios

Describe potential partnership scenarios

Detailed analysis of production and business processes of various P&P industry segments17 workshop sessions, 8 months

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PaperMachine Simplex

Sheeter

SimplexSheeter

Winder

Rewinder

Folio (Customer sizes)/ CutSize (Standard sizes)Sheets

Rolls

PalletWrap

RollWrap

Warehouse

Custom

ers

CoaterRe-

reelerSC

Winder

Not all machines are displayed on this slide

Material Flow Example – Fine Paper

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Linerboard Example

CustomerOrder Entry

ATPCheck

Prod. Plan.Winder

Prod. PlanPaper Mach.

PlanningPulp

ConfirmationRoll

ConfirmationJumbo

RetrimReallocation

Tracking QMDeliveryBilling /

Invoicing

Transport.Planning

WM

Costing (FI, CO/PA)

• Evt. stock transferorder from box plant

• VMI

„Reel Registration“ „Mother Reel Registration“

Detail SchedulingPulp

Forecast orReplenishment

CTPCheck

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AG

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IT and Organizational Pain Points

Merger / Divestment

How to facilitate easy integration in merger/divestment cases: a new mill to integrate in an existing corporate system; an existing mill to de-couple and join another company

Standardised ERP & MES products rolled out in parallel

System architecture

If more and more tasks are moved into a central planning system, it has to be assured by the technical system architecture that the mills can be operated 24 x 365

If the central system requires mill information for decision making, it has to be assured that the technical system architecture provides a unbreakable data flow

Warehouse management:

Mill warehouses 24 x 365, often also integrated with the automation systems (ramp controls, wraplines, etc.). From this point of view, makes sense to be in the mill system. But what is the sufficient level of integration to SAP for things like inventory valuation?

Taskforce results and recommendations presented to management

Agreed to continue to concrete actions:

Pilot customers

Integrated scenarios refined

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Dynamic CTP + order profitability

ABB ProductionExecution

WraplineWarehousing

Shipping

Sheeting

ReelProcessing

Paper MachineDry End

WIPStorage

Rolls

APO

ATP/CTP Block planning Demand Forecasting

ATP/CTP Check 80%

Pallets

DeliveriesWarehouse Status

ConfirmedOrders

Rolls

ProductionStatus

ProductionStatus

Patterns Patterns

Patterns

RewinderRunSchedule

RunSchedule

Rolls

SAP ERP

Reels

Industrial IT Production Planning

Trim & Finishing operationsOptimization

RollsReelsWinder

PTPCheck20%

Run Scheduling1-2 weeks, dynamic

Schedule OptimizationPTP

ABB ProductionScheduling

SAP SalesDistributionPlanning

ConfirmedOrdersOptimized Run Schedule

OptimizedBlock ScheduleAllocations/Replenishment

Forecasts

ABB-SAP Joint Solution

Concrete developmentABB CPM Connector for Pulp & PaperABB ECS frameworkSAP Connectivity and Netweaver certification

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ECS – Overview

In operation since 2004 in ABB’s Circuit Breaker plant in Dalmine, Italy

Based on

.NET technology

- 95

Any RDBMSDatabase

ABB ControlsDevices 3rd party controls

ABB Historian 3rd party Historian

ABB CPM

Database

Middleware

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ECS is ABB’s standard for integration to SAP

Chemicals,

Pharma, F&B

Metals Pulp &

Paper Oil & Gas

Offshore

800xA BatchCPM@Metals CPM for Paper PIMS apps.for O&G

Cement &

Minerals

KnowledgeManager

CPM

DCS

Oil & Gas

Onshore

SCADA Vision


800xA

ABB and 3rd party control systems and historians

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Connecting to SAP – View from 800xA

In 800xA, the structure required to call the selected SAP function is imported as a set of Aspect Objects.

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Connecting to SAP – View from 800xA

The complete SAP table is now available in 800xA, and we can “subscribe” to SAP data in the same manner as with processData.

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ECS – Enterprise Connection Solution

Open technology

Reduced risk

No need to rip and replace

Lower TCO with simpler systems Integration

Point to Point Interfaces ECS Benefits

ERPCRM

E Business

Plant Floor Systems

Business Systems

SCM

Legacy

EnterpriseInterface

Business Solution

ECSPlant

Interface

ERP CRM SCM

xMII

ABB and 3rd party control systems, historians and CPM

Integrated Composite

Applications

Services Based Integration

MES

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Industrial IT - Summary

800xA includes a very comprehensive flexible batch solution

Information Management as info system with excellent reporting and analyses tools

ECS incorporates MES functionality and ERP connections to e.g. SAP

800xA is flexible to delivery of automation solutions that includes the “supply of” or “interface to” third-party COTS software products

industrial it system 800xa isa-95/s88 standards batch information management mes functionality

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