NORMA ISA 95Enterprise-Control System Integration StandardEnterprise-Control System Integration Standard

B2MMLB2MMLBusiness To Manufacturing Markup LanguageBusiness To Manufacturing Markup Language

2

Companies Participating in SP95Companies Participating in SP95

ABBArla FoodsAspenTechDupontEli LillyEmerson Process ManagementFluor General ElectricInvensys-WonderwareLighthammer

Lund University, SwedenLyondell – EquistarMicrosoftNestleNovo NordiskProctor & GamblePurdue UniversityRockwell AutomationSAPSiemensYokogawa

3

Why was ISA-95 Created?Why was ISA-95 Created?

Integration of business and manufacturing systems is difficult Different Automation & IT cultures, knowledge bases

Lack of consensus and models to follow for integrationIncrease in business needs to integrate manufacturing sites with business systemsBusiness drivers: Supply chain optimization Asset efficiency Agile manufacturing Available to Promise & Available to Profit

4

What ISA-95 OffersWhat ISA-95 Offers

Framework for integration projects

Separation of business processes from manufacturing processes

Focus on functions, not systems, organizations or individuals

5

SITE

AREA AREA AREA

CONTINUOUSPRODUCTION

UNIT

DISCRETEPRODUCTION

LINE

ENTERPRISE

ISA-95 ScopeISA-95 Scope

95.0395.03

95.01 & 295.01 & 2

BATCHPROCESS

CELL

6

Information of InterestInformation of Interest

FunctionsOutside the

Control Domain(e.g. Production Scheduling)

(e.g. Production Schedule and Production Results)

Information Flows of interest

FunctionsWithin the

Control Domain(e.g. Equipment Monitoring)

Enterprise/Control System Boundary

Functions detailed

Functions not detailed

Data flows detailed

Data flows not detailed

7

Categories of InformationCategories of Information

Pro

du

ctio

nR

esp

on

se P

rod

uctio

n

Sch

edu

le

Business Planning &Logistics Information

Pro

du

cti

on

De

fin

itio

n

Manufacturing Operations &Control Information

Pro

du

cti

on

Ca

pab

ility

Resource Availability

Manufacturing Instructions, Recipes, BOM,

What to make, when to make it , what to use

What was made and used

8

Major Object ModelsMajor Object Models

Three categories of resources

Personnel Equipment Material (and Energy)

Combined resources (logical view) Process Segments

Four Models / Production-Process-Product Production Schedule Production Performance Capability Definition (by time & by segment) Product Definition

9

Design PatternsDesign Patterns

Resources Class-Instance models

Major Objects Sub-divided into segments

Each segment has personnel, equipment, material, & data components

Properties Few standard object attributes Properties used to permit customization

Necesidades de Importantes empresas del mundo

+Experiencia de los Principales proveedores

de soluciones tecnológicas

=Norma ISA 95

Definición de ModelosDefinición de Modelos

Niveles de Detalle del Modelo

Parte 1: CL 5 Parte 1: CL 5 y 6 Parte 1: CL 6

Parte 1: CL 7. 3-4- 5 Parte 1: CL 7 Parte 1: CL 6.2

5 Hierarchy Models 5.1 Scheduling and control hierarchy 5.2 Equipment hierarchy model

13

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

Scheduling and control hierarchy

Interface addressedParts 1 & 2

Area addressedParts 3 & 4

14

Level 3 activitiestypically deal with

these objects

ENTERPRISE

SITE

AREA

PRODUCTIONLINE

WORKCELL

PRODUCTIONUNIT

PROCESSCELL

UNIT

Level 4 activitiestypically deal with

these objects

Lower level equipment usedin repetitive or

discrete production

Lower level equipment used

in batchproduction

Lower level equipment used

in continuousproduction

STORAGEZONE

STORAGEMODULE

Lower level equipment used

for storage

Equipment hierarchy model

Enhanced in Part 3

Functional data flow model

6 Functional data flow model

OAGi General Meeting ISA-95 - B2MML Briefing 16May 2, 2006

Reference ModelReference Model

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)

Pack Out Schedule

Finished Goods Inventory

Finished Goods W

aiverProcess Data

Short Term Materialand Energy Requirements

Material and EnergyInventory

Production Capability

Production From Plan

Schedule

Incoming material and

energy receipt

Pro

duct

ion

Cos

t

Obj

ectiv

es

Pro

duct

ion

Per

form

ance

and

cos

t

Con

firm

to

ship

Rel

eas

e to

shi

p

QA

Res

ults

Pro

duct

and

Pro

cess

Req

uire

men

ts

Standards and

Customer

Requirements

Standards and Customer

Requirements

In Process WaiverRequest

Process Data

QA Results

Product and P

rocess Know

How

Product and P

rocess Technical Feedback

Mai

nten

anc

e S

tand

ard

san

d M

etho

ds

Ma in te na

n ce Te c hni c alF

eedbac k

Maintenance

Purchase Order

Requirements

Material and

Energy O

rder

Requirem

ents

Incoming

Order

Confirm

ation

Long

Ter

m

Mat

eria

l and

ener

gyre

quire

men

ts

Production O

rders

Availability

Product and P

rocess Information R

equest

Mai

nten

anc

e R

equ

est s

Ma in ten a

nce Res p

ons es

Enterprise/Control

Boundary

Functional data flow model

7 Object Model

7.1 Categories of information 7.3 Production capability information

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Identified Information CategoriesIdentified Information Categories

Manufacturing operations &control information

Production operations, maintenanceoperations, quality operations, etc

Business planning &logistics information

Plant production scheduling,operational management, etc

Productdefinition

information(What must be

defined to makea product)

Productioncapability

information(What resources

are available)

Productionschedule

information(What to

make and use)

Productionresponse

information(What was

made and used)

7.1.1Production capability information

7.1.2 Product definition information

7.1.2 Product definition information

7.1.3 Production information

7.1.4 Process Segment capabilities

7.1.4 Process Segment

MODELOS

Objetos

7.3 Production capability information

7.3 Production capability information

28

Personnel ModelPersonnel Model

PersonProperty

PersonnelClass

Hasvalues for

0..n

0..n

0..n

0..n

0..n

0..n

0..n

1..n

HasProperties

of

Is testedby a

Maps to

Defined by

Records theexecution ofDefines a

procedure forobtaining a

Person

PersonnelClass Property

QualificationTest

Specification

QualificationTest

Result

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Persons and Personnel ClassesPersons and Personnel Classes

Supervisor LaborerProfessionalEngineer

Operator PumpMechanic

Draftsman

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

QualificationTest

QualificationTest Results

30

Equipment modelEquipment model

MaintenanceWork Order

May be generated for0..n

1..1

1..1

1..1

EquipmentProperty

EquipmentCapability TestSpecification

Hasvalues for

0..n

0..n

0..n

0..n

0..n

Equipment0..n

0..n1..n

HasProperties

of

Is testedby a

Maps to

Defined by

Records theexecution of

0..n 0..n May result in

0..1

May be made up of

Is against

Is madeagainst

0..n

0..n

Defines aprocedure forobtaining a

EquipmentCapability Test

Result

MaintenanceResponse

EquipmentClass Property

MaintenanceRequest

EquipmentClass

31

Equipment and ClassesEquipment and Classes

Mixing ReactorHeating Reactor

HR101 HR102 HMR101 MR101 MR102

MaintenanceRequest

MaintenanceWorkOrder

CapabilityTest

CapabilityTest Results

MaxTemp =300 F

Capacity=5000 Gal

Shearing=TRUE

Capacity=3000 Gal

32

Material modelMaterial model

MaterialSublot

May be made upof sublots

0..n

0..n

0..n

MaterialDefinitionProperty

QA TestSpecification

MaterialDefinition

Hasvalues for

0..n

0..n

0..n

0..n

0..n

Material Lot

QA TestResult

1..1

0..n1..n

HasProperties

of

Is testedby a

Maps to

Defined by

Records theexecution of

Made up of

MaterialClass

Property

MaterialClass

0..n

HasProperties

of

0..n

Definesa grouping

Is associatedwith a

Maymap to

Defines aprocedure forobtaining a

Material LotProperty

33

Material Definition ExampleMaterial Definition Example

LotHCL-50-100019

pH1.0

Density1.05

ColorStraw

Purity99.5%

Material

Definitio

n

Material DefinitionHCl 50%

Color PuritypH

Material ClassHCl Acid

Material

Class

Density

SublotHCL-50-100019

Barrel 15

LocationQA TestSpecification

QA TestResults

34

Process Segment ModelProcess Segment Model

People

Materials

Equipment

Segments

Personnel resources managed for production

Equipment resources managed for production

Material resources managed for production

Collections of resources, used together for production, at the granularity needed for business level scheduling and costing

Process Segment ModelProcess Segment Model

36

Process SegmentsProcess Segments

Business view of production

Inventory trackedfor Active Ingredient

Inventory trackedfor Pills

Inventory trackedfor Pill Packs

Pharmaceutical Manufacturing(3 Segments)

MakeActive

Ingredient

MakePills

PackageDosesRaw

MaterialsFinishedProducts

Know throughput,resources and time to

make Active Ingredient

Know throughput,resources and time to

make Pills

Know throughput,resources and time to

make Pill Packs

7.4 Product definition information

7.5 Production information

7.5.1 Production Schedule ModelProduction Schedule Model

7.5.2 Production Performance Model7.5.2 Production Performance Model

39

Production, Capability, ProductProduction, Capability, Product

ProductionSchedule

ProductionPerformance

What to make and resources to use

What was made and resources actually used

ProductDefinitions

What is available for use for production

What is needed to make a product

Product

Time

Capability/Capacity

40

Production ScheduleProduction Schedule

People

Materials

Equipment

Segments

ProductDefinitions

ProductionSchedule

41

7.5 Production Schedule Model7.5 Production Schedule Model

PersonnelRequirement

EquipmentRequirement

Material ProducedRequirement

PersonnelModel

EquipmentModel

MaterialModel

Corresponds toelement in

Corresponds toelement in

Corresponds toelement in

May contain

0..n 0..n0..n0..n

1..n

PersonnelRequirement

Property

EquipmentRequirement

Property

Material ProducedRequirement

Property

1..n 1..n 1..n

ProductionSchedule

ProcessParameter

Material ConsumedRequirement

Corresponds toelement in

0..n

Material ConsumedRequirement

Property

1..n

ConsumableExpected

0..n

ConsumableExpectedProperty

1..n

SegmentRequirement

1..n

Is made up of

Is made up of

Is associatedto either

ProductProduction

Rule

RequestedSegmentResponse

Correspondsto a

Correspondsto a

ProductionParameter

ProductionRequest

0..n

ProcessSegment

ProductParameter

42

Production Performance Production Performance

People

Materials

Equipment

Segments

ProductDefinitions

ProductionSchedule

ProductionPerformance

43

7.5 Production Performance Model7.5 Production Performance Model

PersonnelActual

EquipmentActual

Material ProducedActual

ProductionData

PersonnelModel

EquipmentModel

Material

Model

Corresponds toelement in

Corresponds toelement in

Corresponds toelement in

May contain

0..n 0..n0..n0..n

1..n

PersonnelActual

Property

EquipmentActual

Property

Material ProducedActual

Property

1..n 1..n 1..n

ProductionPerformance

ProductionResponse

Material ConsumedActual

Corresponds toelement in

0..n

Material ConsumedActual

Property

1..n

ConsumableActual

0..n

ConsumableActual

Property

1..n

SegmentResponse

1..nIs made up of

Is made up of

ProcessSegment

Correspondsto a

Resumen

45

Production Schedule ApplicationProduction Schedule Application

ISA-95ProductionSchedule

Setpoints&

Flowpaths

Dispatching

SetupInstructions

BatchSchedule

ContinuousPremix

Batch ProductionProcess

DiscretePackaging

Multiple levels of planning & scheduling

Quarterly

Monthly

Weekly

Dispatch to Production

Production schedules often must be split to multiple control systems & multiple process types

OAGi General Meeting ISA-95 - B2MML Briefing 46May 2, 2006

ISA-95 Functional HierarchyISA-95 Functional Hierarchy

Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc

ManufacturingOperations & Control

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

ContinuousControl

Level 4

Level 3

Levels2,1,0

Parts 1, 2 & 5focus on thisInterface

DiscreteControl

BatchControl

Parts 3 & 4 Focus onManufacturingOperations

OAGi General Meeting ISA-95 - B2MML Briefing 47May 2, 2006

Datacollection

Executionmanagement

Resourcemanagement

Dispatching

Tracking

Operationsresponse

Detailedscheduling

Operationsrequest

Definitionmanagement

Analysis

Operationscapability

Operationsdefinitions

ISA-95 Part 3 Generic ModelISA-95 Part 3 Generic Model

48

4 Sets of Level 3 Activities4 Sets of Level 3 Activities

ResourseManagement

QualityManagement

InventoryManagement

ProductionManagemen

t

datacollection

executionmanagement

resourcemanagement

dispatching

tracking

Detailedscheduling

definitionmanagement

performanceanalysis

datacollection

executionmanagement

resourcemanagement

dispatching

tracking

Detailedscheduling

definitionmanagement

performanceanalysis

datacollection

executionmanagement

resourcemanagement

dispatching

tracking

Detailedscheduling

definitionmanagement

performanceanalysis

datacollection

executionmanagement

resourcemanagement

dispatching

tracking

Detailedscheduling

definitionmanagement

performanceanalysis