isa 95 overview

7/31/2019 ISA 95 Overview

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2004 GE Fanuc Automation All rights reserved.

Charlie GiffordSolutions Architect-Lean Performance Mgt.

Global Professional Services Business

Office (208) 788-5434 Fax: (208) 788-5690

Cell (208) 309-0990 [email protected]

Intelligent Production Management Seminar

An ISA95 Overview:

Workflow and System Modeling for21st Century Manufacturing Flexibility


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Seminar Overview

Goal of the ISA95 Effort Collaborative Production Management (CPM)

Business Drivers ISA95 Direction and Scope of Plant Model Agreement of Control Responsibility

Object Model

Four categories of resources

Four categories of information

Part 3: Manufacturing Operations Model

Question: What does this mean for actualproject implementation? XML - schemas ERP-Proficy connector ISA95 Status


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Goals

Understand the market drivers for ISA95 Understand the two points of view for supply

chain optimization ISA95 Value and Direction Agreement of Control Responsibility

Understand Object Model Proficy is ISA95 Compliant

Understand ISA95 Business Value


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Ever Had This Happen?

The VP of IT announces that the ERPinstallation is done, Now the only thing left to do

it tie into the plant systems!PS: The interface solution is trivial and was due

yesterday.

To reduce inventory or meet your companysMake-To-Order strategy, you need to run very

short schedules (multiple per day) and very fastend of production responses (immediate)!

PS: Dont increase inventory or staff


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BusinessLogistics

ManufacturingOperations

Goals of the 95 Effort

Integration of business (logistics)systems to manufacturing is

hard to do

Different systems, cultures,

terminology, timing... Benefits expected from standardization

and documentation of best practices


6/51 2004 GE Fanuc Automation All rights reserved.

BusinessLogistics


Goals of the 95 Effort

Effective operation of manufacturing ishard to do

MES solutions are too related toprocessing methods and too industry-

specific Benefits expected from standardization

and documentation of best practices



Manufacturing Process TypesDrive Complex System Requirements

Production Types

Discrete Manufacturing

Batch ProcessingContinuous Processing

Workorder Mgt Categories

Engineer-to-Order

Make-to-Order

Make-to-Stock

The 9 combinations (or hybrids) of Production Type and Work OrderManagement each have a different set of business rules processes

in their supply chain, enterprise and production base

ETO MTO MTS



The Goal of the Industrial Enterprise*

is to make money. Make more money now andin the Future The 3 Basic Metrics:(T) Throughput :

The rate: the system generates money through sales(I) Inventory (and investments) :

The money the system invests in things it intends to sell(all saleable resources: material, equipment)

(OE) Operational Expenses :

The money the system spends to transform Inventory

into Throughput$$$

Throughput

$$$Operational Expenses

$$$Inventory

Money coming in Money tied up inside Money going out

*Goldratt, The Goal, page 58-62



SuppliersSupplier

Supplier

Plan

Customer

CustomersCustomer

MakeDeliverSource Make

DeliverMakeSourceDeliver SourceDeliver

Internal or External Internal or External

Your Company

Source

ReturnReturnReturnReturn

CPM Business DriversBusiness Processes and Metrics

SCORs Five Distinct Management Processes

Supply-Chain Council, 2001 All rights reserved

Corporate approach set by optimization view

Supply Chain vs. Plant Optimization: 60-80% Liquid Assets are in Supply Chain 60-80% Tangible Assets in your Plants



CPM Business Drivers Summary:Liquid Asset Optimization

Supply chain optimization

Capable to promise Reduced cycle time

Asset efficiency

Agile Manufacturing

Supply Chain & Operator Empowerment

Improved Planning



CPM Business Drivers Summary:Tangible Asset Optimization

Increase:

Plant Throughput

Product quality

Rework efficiency

Equipment utilization

Line uptime

Event communication and response



CPM Business Drivers Summary:Tangible Asset Optimization

Decrease:

Non-value-add product costs

Plant inventory and work-in-process (WIP) Regulatory reporting costs

Rework (eliminate)

Waste: material and human resources Time-to-volume on a new product introduction (NPI)

Time-to-theoretical yield and cycle time on an NPI

Line changeover time

Maintenance: costs, response time, and downtime

Total cost of ownership for IT and controls systems



ISA 95 Provides Direction for Optimization

The ANSI/ISA 95.00.01 Enterprise - Control SystemIntegration - 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 - Part 3: Activity Models of

Manufacturing Operations Management Draft ISA 95.00.04 - Part 4: Object Models and Attributes

of Manufacturing Operations Management

Draft ISA 95.00.05 - Part 5: Business to ManufacturingTransactions



SITE

AREA AREA AREA

ISA95ISA95StandardStandard

CONTINUOUSPRODUCTION

UNIT

DISCRETEPRODUCTION

LINE

ENTERPRISE

Scope

ISA S88ISA S88

StandardStandard

BATCHPROCESS

CELL From ISA-95 Copyright ISA 2004.Used with permission. www.isa.org



SITE

AREA AREA AREA

ISA95ISA95StandardStandard

CONTINUOUSPRODUCTION

UNIT

DISCRETEPRODUCTION

LINE

ENTERPRISE

Scope

95.0395.03

95.01 & 95.0295.01 & 95.02ISA S88ISA S88

StandardStandard

BATCHPROCESS

CELL



Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc

ManufacturingOperations & Control

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

BatchControl

DiscreteControl

ContinuousControl

Level 4

Level 3

Levels2,1,0

ISA95.01 Levels

Interface addressedin the ISA 95.01 andISA 95.02 standard

Area addressedin the ISA 95.03standard

From ISA-95 Copyright ISA 2004.

Used with permission. www.isa.org



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 & ControlDispatching Production, Detailed Production

Scheduling, Reliability Assurance, ...

BatchControl

DiscreteControl

ContinuousControl

Level 4

Level 3

Levels2,1,0

ISA95.01 Levels


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ISA 95 Part 1 and Part 2 ExchangedInformation

Information must efficiently and effectivelycross the boundary between business

and manufacturing systems



S95 Parts 1, 2 and 3

Part 1 defines: standard terminology and object models

scope of the manufacturing control domain

functions associated with the interface betweencontrol functions and enterprise functions

information that is shared betweencontrol functions and enterprise functions

Part 2 defines:

attributes for all objects that are defined in Part 1. The objectsand attributes are used for exchange of information between

different systems and used as the basis for relational databases.Part 3 defines:

the functions and activities at level 3(Production Management layer)



DomainDefinitions

Information

Flows of Interest

Functionsof Interest

Information

Definitions

Functionsin Domains

ISA 95 Models and Definitions

Categories of

Information



S95 FunctionalEnterprise-Control Model

Procurement(5.0)

ProductionScheduling

(2.0)

Material andEnergy Control

(4.0)

ProductInventory

Control(7.0)

Product CostAccounting

(8.0)

QualityAssurance

(6.0)

ProductShipping Admin

(9.0)

OrderProcessing

(1.0)

ProductionControl

(3.0)

MaintenanceManagement

(10.0)

Research

Development& Engineering

Marketing& Sales

ISA S95

Part 1&2

From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org


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Identified Information Categories (Flows)

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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Agreements on the Control Responsibility

Drawing the line between the Level 3 and the Level 4 functions

A function is in the control domain if:

The function is critical to:> maintaining regulatory compliance.

Includes such factors as safety, cGMP, and environmental compliance

> plant safety

> product quality

> plant reliability

Why ?

Where is the responsibility ?

Who has the responsibility ?

Where are firewalls needed (policy and technology) ?

dS95 03 P d ti C t l F ti


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Productionresource

management

Productioncapability

Analysis

Productiondata

collection

Productionexecution

Production

dispatching

Productiontracking

Productionperformance

Detailedproductionscheduling

Productionschedule

Level 2 Process Control

Productdefinition

management

Productdefinition

dS95.03 Production Control FunctionsWhere is the Line of Responsibly?

Section 14: Logistics vs. Operations?


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Determine Lines of Responsibility vs.Technical Integration between Level 3 and 4

The functions critical to Level 3:

Product quality, Plant safety, Plant reliabilityand Maintaining regulatory compliance

T

Level 2

Maintenance Production Quality Inventory

R

Productiondata

collection

Productionexecution

Productionresource

management

Productiondispatching

Productiontracking


Detailedproductionscheduling

Productionschedule

Productdefinition

management


analysis


Productdefinition

Maintenanceresource

management

Maintenanceresponse

Detailedmaintenancescheduling

Maintenancerequest

Maintenancedefinition

management

Maintenancecapability

Maintenanceanalysis

Maintenancedefinitions

Maintenancedata

collection

Maintenanceexecution

Maintenancedispatching

Maintenancetracking

Inventoryresource

management

Inventoryresponse

Detailedinventory

scheduling

Inventoryrequest

Inventorydefinition

management

Inventoryanalysis

Inventorycapability

Inventorydefinitions

Inventorydata

collection

Inventoryexecution

Inventorydispatching

Inventorytracking

Qualityanalysis

Qualitytest resourcemanagement

Quality testresponse

Detailedquality testscheduling

Quality testrequest

Qualitydefinition

management

Quality testcapability

Qualitydefinitions

Qualitytest datacollection

Quality testexecution

Quality testdispatching

Quality testtracking


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4x4 Object Model Describes Data Flows

Fourcategories of resources Personnel

Equipment

Material (and Energy)

Process Segments

Fourcategories of information Capability & Capacity Definition

Product Definition

Production Schedule

Production Performance


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S95 FunctionalEnterprise-Control Model

Procurement(5.0)


(2.0)


(4.0)

ProductInventory

Control(7.0)


(8.0)

QualityAssurance

(6.0)


(9.0)

OrderProcessing

(1.0)

ProductionControl

(3.0)

MaintenanceManagement

(10.0)

Research

Development& Engineering

Marketing& Sales

ISA S95

Part 1&2

From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org




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Four Resource Object Models

People

Materials

Equipment

Personnel resources managed for production

Equipment resources managed for production

Material and Energy resourcesmanaged for production

Process Segments

Business view of production processes


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Persons and Personnel Classes withRequired Properties The picture below represents person and

personnel class information

Supervisor Laborer ProfessionalEngineer

Operator PumpMechanic

Draftsman

Joe Smith - ID#12345Sally Jones- ID#12344

QualificationTest

QualificationTest Results

St d d T i l F


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Level 3activitiestypicallydeal with

theseobjects

ENTERPRISE

SITE

AREA

PRODUCTIONLINE

WORKCELL

PRODUCTIONUNIT

PROCESSCELL

UNIT

Level 4 activitiestypically deal with

these objects

Lower levelequipment usedin repetitive or

discrete operations

Lower levelequipment used

in batch operations

Lower levelequipment usedin continuous

operations

STORAGEAREA

STORAGEUNIT

Lower levelequipment used

in inventory

operations

Standard Terminology ForEquipment Classification


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Material Classes, Definition, Lots,Sublots, and Properties

Standard terminology for defining materialinformation

LotHCL-50-100019

pH1.0 Density1.05 ColorStraw Purity99.5%

Material

Definition

Material DefinitionHCl 50%

Color PuritypH

Material ClassHCl Acid

Material

Class

Density

SublotHCL-50-10001

Barrel 15

LocationQA TestSpecification

QA TestResults


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Process Segments

The business view of production

Pharmaceutical Manufacturing(3 Segments)

Make

ActiveIngredient

MakePills PackageDoses

Inventory trackedfor Active Ingredient

Inventory trackedfor Pills

Inventory trackedfor Pill Packs

RawMaterials

FinishedProducts

Know throughput,resources and time to

make Active Ingredient


make Pills


make Pill Packs


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Capability, Product, Schedule, andPerformance Information

Product

Definitions

Production

Schedule

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 andresources actually used

Product

Time

Capability/Capacity


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Production Capability Models

People

Materials

Equipment

Segments

Product

TimeCapabilities

What is available

- Currently- In the future- Per resource- Per segment of

production

- What is available- What is unattainable- What is committed


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Production Capability & Capacity

Capa

city

Productio

nCapacity

Unattainable Capacity

Available Capacity

Committed Capacity

Time

Current Capacities

Current Production Capacity


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Product Definition

Shared information about each product betweenLevel 3 and 4

References manufacturing instructions> For Continuous may be flow sheets

> For Batch may be site or master recipes

> For Discrete may be setup or assembly instructions

Defines all materials used by manufacturing


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Product Definition

References the Bill of Materials References the Bill of Resources

Defines resources required per segmentEquipment

Personnel

Material

Per Product Definitions


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Per Product Definitions

Asse

mbly

Instru

ction

s

Production RulesProduction Rules

e.g.e.g.

10 Speed Bicycle10 Speed Bicycle

BillO

f

Resourc

es

Bill Of ResourcesBill Of Resources

e.g. 10 Speed Bicyclee.g. 10 Speed Bicycle

BillO

f

Mater

ials

Bill Of MaterialsBill Of Materials

e.g. 10 Speed Bicyclee.g. 10 Speed Bicycle

ProductSegments

Frame : 1Wheels : 2

Chain : 1Seat : 1Handlebars :1Brake Pads : 4...

ManufacturingBill

FrameAssembly

Frame

Type

FinalAssembly

Seat

Height

Color

Paint

Product Definition


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Production Schedule

People

Materials

Equipment

Segments

Production

Schedule

What to makeWhat to make-- Priority and/or datesPriority and/or dates

-- What to use:What to use:--MaterialsMaterials--EquipmentEquipment

--personnelpersonnel-- Production parametersProduction 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 ProducedExpected ProducedMaterialMaterial

Expected ConsumedExpected ConsumedMaterialMaterial

Expected PersonnelExpected Personnel

Expected EquipmentExpected Equipment Production ParametersProduction Parameters


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People

Materials

Equipment

SegmentsProduction

Performance

What was madeWhat was made

-- What material wasWhat material was

actually producedactually produced

-- What materials wereWhat materials wereactually consumedactually 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 MaterialProduced MaterialActualActual

Consumed MaterialConsumed MaterialActualActual

Personnel ActualPersonnel Actual Equipment ActualEquipment Actual

Production DataProduction Data

ISA95 P t 3 A ti it M d l f


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INVENTORY

OPERATIONS

INVENTORY

OPERATIONS

MAINTENANCE

OPERATIONS

PRODUCTION

OPERATIONS

QUALITY

ASSURANCE

OPERATIONS

Procurement(5.0)


(2.0)


(4.0)

ProductInventory Control

(7.0)


(8.0)

QualityAssurance

(6.0)

ResearchDevelopment

and Engineering


(9.0)

OrderProcessing

(1.0)

Marketing& Sales

ProductionControl

(3.0)

Maintenance

Management(10.0)

ISA95 Part 3: Activity Models ofManufacturing Operations

In Development

Draft 17 Available

d95 03 M f t i O ti


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d95.03 Manufacturing OperationsFunctions

Productionresource

management


Analysis

Productiondata

collection

Productionexecution

Production

dispatching

Productiontracking


Detailedproduction

scheduling

Productionschedule

Level 2 Process Control

Productdefinition

management

Productdefinition

Equipment and ProcessSpecific Production Rules

Equipment and ProcessSpecific Data

OperationalResponses

OperationalCommands



B i l * (APICS t i l )


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Business plan* (APICS terminology)(Per Product Line, Per Time Very Long Time Horizon)

Demand plan* (APICS terminology)(Per Product, Per Time Long Time Horizon)

Production plan* (APICS terminology)(Per Product, Per Time - Long Time Horizon)

Production schedule (Master production schedule - APICS terminology)(Per Site/Area, Per Product, Per Time Medium Time Horizon)

Detailed production schedule(Per Workcenter, Per Product/Intermediate, Per Time Short Time Horizon)

2.4 Production scheduling activity (ISA-95.01)

Detailed production scheduling activity (ISA-95.03)

1.1 Production Forecasting Activity (ISA-95.01 )

Production Dispatch list(Per Workcenter or Workcenter element, Per produced item, Per Time Very Short Time Horizon)

Production dispatching activity (ISA-95.03)

* Not in the scope of this standard

Production

ScheduleFlow

Oth E t i A ti iti i


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Major

ActivitiesWithin


QualityOperations

MaintenanceOperations

ProductionOperations

Level 4

Level 3

Level 2

Managementof Configuration

Managementof Information

Managementof Security

Managementof Documentation

Managementof Compliance

InventoryOperations

Other Enterprise Activities inManufacturing Operations Some actives are not specific to manufacturing

ISA-95.03 lists references to standards in these areas

Activity detailed

Activity not detailed

Activity outside scope

Q ti Wh t d thi f t l


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Question: What does this mean for actualproject implementation?

Answer: XML Schemas:

Common Language and Common Protocol

between Levels 3 and 4


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B2MML - Business to Manufacturing

Markup Language XML-based implementation of ISA95 standard developed bythe volunteer effort of the WBF's XML Working Group

Provides a set of XML schemas based upon theANSI/ISA 95family of standards. The schemas were written using the WorldWide Web Consortiums XML Schema language (XSD)

Used to integrate ERP and supply chain management systemswith manufacturing systems

Formal way to document information and agreements

NOTE: Does not define TRANSACTIONS, just the data to beused inside other transaction systems (e.g. OAG)

B2MML S h


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Common Schema Equipment Schema

Material Schema Personnel Schema

Process Segment Schema

Product Definition

Production Capability


Production Schedule

Maintenance Schema

B2MML: Schemas

Wh XML ?


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Why XML ?

Openness Simplicity

Self-describing

Interoperability

Structure

Extensibility

Platform independency

X-Path Query Language Self-documenting

Fully Extensible

ERP Proficy Connector


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Proficy Transaction Table

S95 Connector

ERP System

XML Input Schemas B2MMLEquipmentMaintenanceMaterialProcess Segment

Product DefinitionProduction CapabilityProduction PerformanceProduction Schedule

XML Standard Schema

Transaction Table compatible

ERP - Proficy Connector

S95 B i V l


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S95 Business Values Easier Level 3 product comparison, selection, and replacement

using consistent models and language across all industries

Enhanced protection of end users intellectual property through

consistent supplier product functional partitioning

Easier flow of information from consistent messaging between

business and production systems

Faster implementation of integration projects by enablingindustry-wide standards using current technologies

LARGE Reduction implementation and maintenance costs forenterprise integration through the use of single interface schema

Stat s


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Status

ISA95.00.01 & ISA.95.00.02 available IEC/ISO 62264-1 available from IEC & ISO ISA 95.00.03 /.04/.05 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

isa 95 overview

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