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Practical Enterprise Modelling:
ISA 88 and ISA 95 standards
IEC SB3 Sponsored SeminarWorkshop on Industrial Automation Objects
3-4 April 2001, Geneva, Switzerland
Jean Vieille, ConsultantISA SP88 & SP95 committees member
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Agenda
ISA 88 and 95 in SCM and Production Scheduling
ISA 95 : Enterprise-Production Communication
ISA 88 : Modular Control
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ISA 88 and 95 in SCM and Production
Scheduling
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Market / Customer driven production
ProductDevelopment
ResourcesEngineering
ProductionSchedule
Market /Customerdemand
Classical Enterprise
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Agile Enterprise
ProductDeveloment
ProductionSchedule
Market /Customer
demand
ResourcesEngineering
Production
Schedule
EnterpriseSystem 1
ManufacturingControl System 1
ManufacturingControl System 2
Company 1 with
manufacturing
Company 2 with No manufacturing
EnterpriseSystem 2
ManufacturingControl System 3
Company 3 Contract manufacturer
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S95.01 Scope
Source: ISA dS95.01 Enterprise/Control System Integration
Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc
Level 4
ManufacturingOperations & Control
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
Level 3
Levels2,1,0
BatchControlSystems
ContinuousControlSystems
DiscreteControlSystems
Interface addressedin ISA 95.01 / 02
dS95.03 Area
S88
Business LogisticsSystems
(ERP)
ManufacturingOperations Support
(MES)
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Manufacturing in The Supply Chain
The Supply Chain The network of activities in a company that take place from
customer order to customer delivery
Customer
Order Entry
Scheduling
Suppliers
Production Distribution
Delivery
Suppliers
Suppliers
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S95/S88 and The Supply Chain
Consum
ers
Suppliers
MaterialsPurchasing
ProductDevelopment
ProductionPlanning
ManufacturingOperations
OrderManagement
Distribution& Logistics
Enterprise Resource Planning / Supply Chain ManagementCustomerService
Warehouse &
TransportationManagement
P
E
C
A
R
Maintenance
Management
P
E
C
A
R
Order &Inventory
Management
P
E
C
A
R
Production
InformationManagement
ProductionPlanning andScheduling
RecipeManagement
ProcessManagement
UnitSupervision
ProcessControl
SP95.01 Enterprise / Control System Integration
Process Management
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S88 et S95
Enterprise A
Product
S95
Enterprise X Manufacturing
S88
ProcessCell X1
S88
ProcessCell X2
Enterprise Y Manufacturing
S88
ProcessCell Y1
S88
ProcessCell Y2
S88
Enterprise B
Product
S88
Quality
Maintenance
S95
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S95.01 Production Schedule
StructureProduction Schedule
Production Request
Segment Requirement
ProductionParameter
PersonnelRequirement
EquipmentRequirement
MaterialConsumed
Requirement
MaterialProduced
Requirement
ConsumableExpected
A Production Schedule is madeup of 1..n Production Requests
A Production Request is made upof 0..n Segment Requirements
A Segment Requirement maycontain 0..n of each
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Mixed Format Schedule Application
S95.01
ProductionSchedule
Setpoints&
Flowpaths
WorkDispatching
SetupInstructions
S88.02Schedule
Entry
ContinuousPremix
Batch ProductionProcess
DiscretePackaging
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S95 in Production System Lifecycles
ProductionSchedule
ProductionCapabilities
ProductDevelopment Resources
Engineering
ProductDefinition
Resources
ProcessSegments
ProductSegments
Segment
Requirement
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S88 in Production System Lifecycles
ProductDevelopment
S88 : Recipe
ProductionSchedule
S88 : Schedule
S88 : Resources
ResourcesEngineering
S88 : EquipmentProceduralElements
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ISA 95 : Enterprise Production
Communication
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What is ISA95 ? Status
SP95 committee started in October 1996 ANSI/ISA95.00.01 available from ISA
Submitted to IEC/ISO
Joint Working Group (JWG 15) to be established
ISA 95.00.02 in draft, out for vote
Out for committee ballot and public comment
ISA 95.00.03 in draft
Still under development in the committee
World Batch Forum
Developing XML Schemas for the exchanged information
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Some SP95 Committee Members / Supporters Users
Eli Lilly DuPont Lyondell Chemical Lubrizol Dow Corning Ben & Jerry's Novo Nordisk Bechtel
Rohm & Haas Sterling Tava Technologies EastmanK
Bayer IBM Aurora Biosciences Genemtech
Merck Nestle Pharmacia Procter&Gamble
UOP Vendors
ABB AspenTech Siemens BaseTen
SAP Sequencia InCode Wonderware
ABB Rockwell Yokogawa Foxboro Propack Data
Honeywell FRSI InCode Oracle
Marcam OSI Intellution Schneider Electric GSE System HP IBM GS Microsoft ORSI
General
Purdue Fluor Daniels AMR Jacobs
MESA PDXI NAMUR Keops
KPMG MIT PWC LLC
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Why Did We Start SP95 ?
Integration of business (logistics)systems to manufacturing ishard to do
Different systems, cultures, terminology...
Many benefits expected from standardization and documentation ofbest practices
Effective operation of manufacturing is hardto do
MES solutions are too related to processing methods and tooindustry-specific
Many benefits expected from standardization and documentation of
best practices
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Business Defines the Need
There must always be a business need for informationto be exchanged
Requirements for exchanged information are alwaysdriven by business needs & business processes
Typical Business Drivers: Available To Promise
Reduced Cycle Time
Supply Chain Optimization Asset Efficiency
Agile Manufacturing
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How Does S95* Help?
Separate the businessprocesses from themanufacturing processes
Allow changes in productionprocesses without requiring
unnecessary changesscheduling and logisticsprocesses
Provide a clear demarcationof responsibilities andfunctions
Provide a clear descriptionof exchanged information
* S95 is used as a short form for ANSI/ISA95
Alternate Logistics Strategies
Alternate Manufacturing Strategies
Make
to
Stock
Engineer
to
Order
Configure
to
Order
Make
to
Order
PDXINAMUR
Continuous
Manufacturing
Models
S88.01 SME
Batch
Manufacturing
Models
Discrete
Manufacturing
Models
S95.01
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Scope of S95.01
The definition of the scope of the manufacturing controldomain
A definition of the functions associated with theinterface between control functions and enterprisefunctions
A definition of the information which is shared betweencontrol functions and enterprise functions
Based on the Purdue Reference Model for CIM andMESA model
SP9 01 E i / C l
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SP95.01 Enterprise / Control
Functional Model (PRM)
Procurement(5.0)
ProductionScheduling
(2.0)
Material andEnergy Control
(4.0)
ProductInventory Control
(7.0)
Product CostAccounting(8.0)
Quality
Assurance(6.0)
Research
Developmentand Engineering
Maintenance PurchaseOrder Requirements
ProductShipping Admin
(9.0)
OrderProcessing
(1.0)
Marketing& Sales
ProductionControl
(3.0)
From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org
http://f/lausanne/50/lomag-man.org/normes/normes_isa/documents/2001-04-IEC.ppthttp://f/lausanne/50/lomag-man.org/normes/normes_isa/documents/2001-04-IEC.ppthttp://f/lausanne/50/lomag-man.org/normes/normes_isa/documents/2001-04-IEC.ppthttp://f/lausanne/50/lomag-man.org/normes/normes_isa/documents/2001-04-IEC.ppt8/2/2019 2001-04-IEC
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Domain
Definitions(Responsibility)
InformationFlows of Interest
Functions
of Interest
Categories ofInformation
InformationDefinitions
Functions
in Domains
Elements of Models & Definitions
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Identified Information Categories
Data flowinformation wascategorized
Multiple Venndiagrams used toillustrate theoverlap ofinformationcategories
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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Major Object Definitions
People
Materials
Equipment
Segments
ProductDefinitions
ProductionSchedule
ProductionPerformance
Resources Capability, Product, Production
Product
Time
Capabilities
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Four 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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Material Definition Example
Common material information
LotHCL-50-100019
pH
7.0
Density
1.32
Color
Yellow
Purity
.5%
Material DefinitionHCl 50%
Color PuritypH
Material ClassAcid
Density
SublotHCL-50-100019
Barrel 15
LocationQA TestSpecification
QA TestResults
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Process Segments
Business view of production
PaintInspect
Laborer3x
8 hourInspector
2x.25 Hour
Type =StainlessSteel
CertifiedPainter =TRUE
I-Beam
Assembly
RollersMixingCans
apa y ro uc an ro uc on
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apa y, ro uc , an ro uc onInformation
ProductDefinitions
ProductionSchedule
Production
Performance
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
Capabilities
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Capability Models
People
Materials
Equipment
Segments
Product
Time
Capabilities
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Scheduling
System
MaterialSystem
Manufacturing
System
Per Product Definitions
Production Rulese.g.
10 Speed Bicycle
Bill Of Resourcese.g. 10 Speed Bicycle
Bill Of Materialse.g. 10 Speed Bicycle
ProductSegments
Frame : 1Wheels : 2
Chain : 1Seat : 1Handlebars :1Brake Pads : 4...
ManufacturingBill
FrameAssembly
FrameType
FinalAssembly
SeatHeight
Color
Paint
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Production Schedule
People
Materials
Equipment
Segments
ProductDefinitions
ProductionSchedule
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Production Performance
People
Materials
Equipment
Segments
ProductDefinitions
ProductionSchedule
Production
Performance
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ProductionCapability
CapabilityProperty
ResourceCapability
Production
CapabilityWhat resources
are available
ProductionPerformance
ProductionResponse
SegmentResponse
ActualProperty
ResourceActual
Production
InformationWhat was
made & used
ProductionRequest
SegmentRequirement
RequirementProperty
ResourceRequirement
Production
SchedulingWhat is it to bemade & used
ProductionSchedule
ProductionRule
ProductSegment
SpecificationProperty
ResourceSpecification
Product
DefinitionWhat must be defined
to make a product
ProcessSegment
SegmentProperty
ResourceSegmentCapability
Process
SpecificationWhat can be donewith the resources
Four Models & Segment Resources
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ISA 95.00.02 : Relationship with Part 1
Attribute
Name
Description Examples
ID A unique identification of a specific piece of
e ui ment, within the sco e of the information
exchan ed (Production Ca abilit , ProductionSchedule, Production Performance, )
The ID is used in other arts of the model when
the equipment must be identified, such as the
production capability for this person, or a
production response identifying the equipment.
R7726
Reactor 101
Lathe machine 33
Description Additional information about the equipment.
dISA95.02
EquipmentAttributes
ISA95.01Equipment
model
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ISA 95.00.03 : Level 3 Functions
MESA Definitions Operations and Detailed Scheduling
Production Tracking
Dispatching Production
Resource Allocation and Control
Data Collection and Data Acquisition
Quality Management
Process Management
Performance Analysis
Interface to Document Control
Labor Management
Maintenance Management
d95.03 Definitions Detailed Production Scheduling
Production Tracking
Production Dispatching
Resource Management
Historical Data Management (QA) Product Analysis
Process Analysis
Production Analysis
Product Definition Management
Process Monitoring Manual Operations
Automated Control
d95 03 M f t i O ti F ti
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d95.03 Manufacturing Operations Functions
Production
Capability
Resource
Management
HistoricalData
Management
ProductionExecution
ProductionDispatching
Production
Tracking
Production
Performance
DetailedProductionScheduling
Production
Schedule
ProcessAnalysis
ProductionAnalysis
(QA) ProductAnalysis
ProductDefinition
Management
Product
Definitions
AutomatedControl
ProcessMonitoring
ManualOperations
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ISA 88 : Modular control
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What is ISA 88 ? - Status
Standard ANSI/ISA 88 Batch Control Comit SP88 lanc en 1988
Partie 1 ISA 88.00.01
Publie et disponible lISA et lANSI IEC 61512-1 bilingue disponible auprs de lIEC, lUTE et lAFNOR
Partie 2 ISA 88.00.02
Publication imminente
Version IEC (61512-2) bilingue pour 2001?
Partie 3 ISA 88.00.03
Dbut des travaux
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Automation Challenge
Ideal automation
S88
Capability
Flexibility
Complexity
ManualOperation
TraditionalAutomation
Darin FlemmingLou Pillai
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The Powerful Tyrex
Big brain Centralized design
OK for steady / slow changing
environment Shortcomings
Agility
Availability Refer to first computerized systems
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vs Stupid Bird
Limited intelligence Mostly decentralized design
Local decision making at feather
level Cope well with unexpected
situations
Inherently adaptative structure
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chirpingEatingLove.
Walking
Flying
From Goal to Labor
I know
What/HowTo do
Forecasting,
PlanningAnd Scheduling
Elementary
EquipmentControl
Process
ControlDefinition
Equipment
FunctionalCapabilities
The Goal:
S h d li hi h
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Scheduling hierarchy
MES systemsSCADA systems
ProcessControl
ISA 88
IEC 61512OPC
IEC 61131IEC 61499
EquipmentControl
IEC 61158Fieldbus
Intelligent
Device
Business system
ISA 95
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Product Processing / Equipment Control
How to makethe product using
available
services?
ProcessControl
ISA 88.00.02(PFC)
Production
schedule
R&D IEC 60848IEC 61131IEC 61499IEC 61508IEC61158
EquipmentControl
How to providethe expectedservices taking care ofsafety ?
Equipmentallocation
ISA 88
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ISA 88 Physical Model
Process CellMust contain
May contain
May contain
May contain
May contain
Unit
Equipment Module
Control Module
Enterprise
May contain
May contain
May contain
Site
Area
Equipment
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Equipment Entities -An Object Approach
PhysicalEquipment
InstrumentsBasiccontrolCoordination controlProcedural control
Equipment
Control
EquipmentEntities
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Example of physical modeling
Process Cell
Unit Unit
EMEM EM
CM
EM
CM
CMCM CM CM
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Example of control modules
CM2D4
D3CM1
CM3
CM4
D1
D2
D5
PID PID
PID
HIC HIC
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Why Control Modules
Treating as a control module simplifiesthe interface to this group of objects
FC
FO
Pump
Circulate
Pump toProcess
Stop
Shutdown
CommandsCirculating
Pumpingto Process
Stopped
Shutdown
Status
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Recipe/Equipment Control Separation
Procedure
UnitProcedure
Operation
Phase
is anordered set of[Must Always Exist]
Control RecipeProcedure
EquipmentControl
is anordered set of
is anordered set of
RecipeProcedure
EquipmentPhase
Recipe/Equipment Control Separation
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Recipe/Equipment Control Separation- Typical
Recipe UnitProcedure
Operation
Phase
is anordered set of
Control RecipeProcedure
is anordered set of
is anordered set of
RecipeProcedure
EquipmentPhase
References
Recipe
Recipe
EquipmentControl
Recipe/Equipment Control Separation -
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Recipe/Equipment Control Separation -
Alternate 3
Control RecipeProcedure
RecipeProcedure
EquipmentPhase
References
EquipmentOperation
is anordered set of
Equip. UnitProcedure
is anordered set of
is anordered set of
EquipmentProcedure
EquipmentControl
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Phase Interface Logic
State machine enforcement between recipe phase andequipment phase
A set of services that support commands to theequipment phase
A set of services that support requests from theequipment phase to the recipe phase
RecipePhase
EquipmentPhase
PhaseInterface
Logic
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Phase Interface Logic
Parameters Requests
StatesCommands StateMachine
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Phase Object
Start
Hold
Pause
Resume
Restart
Abort
Stop
Reset
Run
Held
Paused
Stopped
Aborted
Completed
Idle
Parameters
ControlSteps
ControlActionStatus
Running
Aborting
Holding
Pausing
Stopping DataCollection
Requirements
Data
Restarting
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Example Procedural Element States
Hold
Start
Restart
StopAbort
Reset
Reset
Reset
Restarting Holding
Running
StoppingAborting
Pausing
Resume
Pause
Aborted Stopped
Paused
HeldComplete
Final States
Quiescent States
Transient States
Idle(InitialState)
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Exception Handling In Control Actions
ConsoleControl
Inputs to Control Action Logic:- Set manual mode- Command from operator's
console
Field I/O
Exception Logic
Phase
Logic
Control Module/Control
Action State/Mode
Control
Action
ProcessInterlock
SafetyInterlock
Exception Logic
Inhibit manual override(Interlock from phase logic),
Also sent to console to inhibitchoice of manual mode
Control step (command)
The safety interlock logic takes precedence overphase logic or process interlock logic. Typically this
logic, when required, is implemented in anindependent safety interlock system.
The process interlock logic takes precedence
over phase logic and manual override logic.
Typically, this logic is implemented in theDPCS.
Control ModuleEquipment Module
Control Module
Control Module
Control Module/ControlAction State/Mode
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Reaction
Preparation
Tank
A, B or C
Reactor
1 or 2
operator input
= OK to start
S1
S1
T1 T1
Reaction
Preparation
Tank
A, B or C
Reactor
1 or 2
operator input
= OK to start
S1
S1
T1
Sample
OK
T1
Initialize
Charge
Transfer toReactor
SampleInitialize
Receivefrom Prep.
React
Transfer toStorage
ISA 88.00.02 : Procedural Function Chart Unit procedure interactions
Relative timing Height of unit procedure symbol
Vertical placement of symbols
Master recipes do not contain
absolute timing Synchronization points
Arrowheads indicate materialtransfer
Multiple levels of procedures
Encapsulation (contents) of unitprocedure revealed
Provides more detail
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THANK YOU
