Practical Enterprise Modelling: ISA 88 and ISA 95 standards IEC SB3 Sponsored Seminar Workshop on Industrial Automation Objects 3-4 April 2001, Geneva, Switzerland Jean Vieille, Consultant ISA SP88 & SP95 committees member jean-vieille@usa.net

Agenda ISA 88 and 95 in SCM and Production Scheduling ISA 95 : Enterprise-Production Communication ISA 88 : Modular Control

ISA 88 and 95 in SCM and Production Scheduling

Market / Customer driven production Market / Customer demand Classical Enterprise Production Schedule Product Development Resources Engineering

Agile Enterprise Product Develoment Production Schedule Market / Customer demand Resources Engineering Production Schedule Enterprise System 1 Manufacturing Control System 1 Control System 2 Company 1 with manufacturing Company 2 with No manufacturing Enterprise System 2 Manufacturing Control System 3 Company 3 Contract manufacturer

Business Logistics Systems (ERP) Manufacturing Operations Support S95.01 Scope Business Logistics Systems (ERP) Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Level 4 Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... Level 3 Levels 2,1,0 Batch Control Systems Continuous Discrete Interface addressed in ISA 95.01 / 02 Manufacturing Operations Support (MES) dS95.03 Area S88 Source: ISA dS95.01 Enterprise/Control System Integration

Manufacturing in The Supply Chain The network of activities in a company that take place from customer order to customer delivery Scheduling Suppliers Production Distribution Delivery Order Entry Customer

S95/S88 and The Supply Chain Enterprise Resource Planning / Supply Chain Management Suppliers Materials Purchasing Product Development Production Planning Manufacturing Operations Distribution & Logistics Order Management Customer Service Consumers SP95.01 Enterprise / Control System Integration Order & Inventory Management P E C A R Maintenance Management P E C A R Warehouse & Transportation Management P E C A R Recipe Production Production Planning and Information Management Scheduling Management Process Management Unit Supervision Process Control Process Management

S88 et S95 Enterprise A « Product » Enterprise B « Product » S88 S88 Enterprise X «  Manufacturing  » Quality Enterprise Y « Manufacturing » S88 S88 S88 S88 S95 Process Cell X1 Process Cell X2 Process Cell Y1 Process Cell Y2 Maintenance

S95.01 Production Schedule Structure A Production Schedule is made up of 1..n Production Requests Production Request A Production Request is made up of 0..n Segment Requirements Segment Requirement A Segment Requirement may contain 0..n of each Material Consumed Requirement Material Produced Requirement Production Parameter Personnel Requirement Equipment Requirement Consumable Expected

Mixed Format Schedule Application Production Schedule Work Dispatching Setpoints & Flowpaths S88.02 Schedule Entry Setup Instructions Continuous Premix Batch Production Process Discrete Packaging

S95 in Production System Lifecycles Production Schedule Segment Requirement Product Segments Process Segments Product Definition Production Capabilities Product Development Resources Engineering Resources

S88 in Production System Lifecycles Production Schedule S88 : Schedule S88 : Resources S88 : Recipe S88 : Equipment Procedural Elements Product Development Resources Engineering

ISA 95 : Enterprise – Production Communication

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

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

Why Did We Start SP95 ? Integration of business (logistics) systems to manufacturing is hard to do Different systems, cultures, terminology... Many benefits expected from standardization and documentation of “best practices” Effective operation of manufacturing is hard to do MES solutions are too related to processing methods and too industry-specific

Business Defines the Need There must always be a business need for information to be exchanged Requirements for exchanged information are always driven by business needs & business processes Typical Business Drivers: Available To Promise Reduced Cycle Time Supply Chain Optimization Asset Efficiency Agile Manufacturing

Alternate Logistics Strategies Alternate Manufacturing Strategies How Does S95* Help? Alternate Logistics Strategies Separate the business processes from the manufacturing processes Allow changes in production processes without requiring unnecessary changes scheduling and logistics processes Provide a clear demarcation of responsibilities and functions Provide a clear description of exchanged information Make to Order Make to Stock Engineer to Order Configure to Order S95.01 PDXI NAMUR S88.01 SME Continuous Manufacturing Models Batch Manufacturing Models Discrete Manufacturing Models Alternate Manufacturing Strategies * S95 is used as a short form for ANSI/ISA95

Scope of S95.01 The definition of the scope of the manufacturing control domain A definition of the functions associated with the interface between control functions and enterprise functions A definition of the information which is shared between control functions and enterprise functions Based on the Purdue Reference Model for CIM and MESA model

SP95.01 Enterprise / Control Functional Model (PRM) Order Processing (1.0) Product Shipping Admin (9.0) Finished Goods Waiver Product Cost Accounting (8.0) Production Scheduling (2.0) Finished Goods Inventory Material and Energy Receipt (Incoming) Pack Out Schedule Confirm To Ship Release To Ship Capacity Product Inventory Control (7.0) Production Cost Objectives Long Term Material and Energy Requirement.s Production From Plan Schedule Production Performance and Costs Production Control (3.0) Process Data Procurement (5.0) Maintenance Purchase Order Requirements In-Process Waiver Request QA Results Standards Process Data Short Term Material and Energy Requirement.s QA Results Quality Assurance (6.0) Requirements Energy Order Material and Confirmation Incoming Material and Energy Inventory Product and Process Know How Material and Energy Control (4.0) Standards and Requirements Customer Product and Process Information Request Product and Process Requirements Marketing & Sales Research Development and Engineering From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org

Elements of Models & Definitions Domain Definitions (Responsibility) Functions in Domains Functions of Interest Information Definitions Categories of Information Information Flows of Interest

Identified Information Categories Enterprise Information Plant Production Scheduling, Operational Management, etc Data flow information was categorized Multiple Venn diagrams used to illustrate the overlap of information categories Production Capability Information (What is available for use) Product Definition Information (How to make a product) Production Schedule (What to make and use) Production Performance (What was made and used) Manufacturing Control Information Area Supervision, Production Planning, Reliability, Assurance, etc

Major Object Definitions Resources Capability, Product, Production Product Time Capabilities People Product Definitions Equipment Production Schedule Materials Segments Production Performance

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

Material Definition Example Common material information pH Material Class Acid Material Class Density Material Definition Material Definition HCl 50% Color Purity Lot HCL-50-100019 pH 7.0 Density 1.32 Color Yellow Purity .5% Sublot HCL-50-100019 Barrel 15 Location QA Test Specification Results

Process Segments Business view of production Assembly Inspect Paint Laborer 3x 8 hour I-Beam Inspector 2x .25 Hour Mixing Cans Rollers Type = Stainless Steel Certified Painter = TRUE

Capability, Product, and Production Information Time Capabilities What is available for use for production Product Definitions What is needed to make a product Production Schedule What to make and resources to use Production Performance What was made and resources actually used

Capability Models Capabilities People Equipment Materials Segments Product Time Capabilities People Materials Equipment Segments

Per Product Definitions Scheduling System Material System Resources Bill Of Bill Of Resources e.g. 10 Speed Bicycle Bill Of Materials Bill Of Materials e.g. 10 Speed Bicycle Product Segments Frame : 1 Wheels : 2 Chain : 1 Seat : 1 Handlebars :1 Brake Pads : 4 ... Manufacturing Bill Frame Assembly Type Final Seat Height Color Paint Manufacturing System Assembly Instructions Production Rules e.g. 10 Speed Bicycle

Production Schedule People Equipment Product Definitions Materials Segments

Production Performance People Materials Equipment Production Performance Product Definitions Production Schedule Segments

Four Models & Segment Resources Production Capability What resources are available Process Specification What can be done with the resources Product Definition What must be defined to make a product Production Scheduling What is it to be made & used Production Information What was made & used Production Schedule Production Performance Production Rule Production Request Production Response Production Capability Process Segment Product Segment Segment Requirement Segment Response Resource Capability Resource Segment Capability Resource Specification Resource Requirement Resource Actual Capability Property Segment Property Specification Property Requirement Property Actual Property

ISA 95.00.02 : Relationship with Part 1 ISA95.01 Equipment model dISA95.02 Equipment Attributes

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 Manufacturing Operations Functions Product Definition Management Definitions Production Capability Resource Management Historical Data Management Production Execution Dispatching Tracking Performance Detailed Scheduling Schedule Process Analysis Production (QA) Product Automated Control Process Monitoring Manual Operations

ISA 88 : Modular control

What is ISA 88 ? - Status Standard ANSI/ISA 88 « Batch Control » Comité SP88 lancé en 1988 Partie 1 – ISA 88.00.01 Publiée et disponible à l’ISA et à l’ANSI IEC 61512-1 bilingue disponible auprès de l’IEC, l’UTE et l’AFNOR Partie 2 – ISA 88.00.02 Publication imminente Version IEC (61512-2) bilingue pour 2001? Partie 3 – ISA 88.00.03 Début des travaux

Automation Challenge Ideal automation Flexibility S88 Manual Operation Capability Flexibility Complexity Ideal automation Manual Operation S88 Traditional Automation Darin Flemming Lou Pillai

The Powerful Tyrex… Big brain Centralized design OK for steady / slow changing environment Shortcomings Agility Availability Refer to first computerized systems

…vs Stupid Bird Limited intelligence Mostly decentralized design Local decision making at feather level Cope well with unexpected situations Inherently adaptative structure

From Goal to Labor Flying chirping Walking Eating Love. Forecasting, Planning And Scheduling Elementary Equipment Control Process Control Definition Equipment Functional Capabilities The Goal: I know What/How To do chirping Eating Love. Walking Flying

Scheduling hierarchy Business system ISA 95 MES systems SCADA systems IEC 61512 OPC Process Control Equipment Control IEC 61131 IEC 61499 IEC 61158 Fieldbus « Intelligent » Device

Product Processing / Equipment Control IEC 60848 IEC 61131 IEC 61499 IEC 61508 IEC61158 Equipment Control How to provide the expected services… … taking care of safety ? Equipment allocation ISA 88 How to make the product… … using available services? Process Control ISA 88.00.02 (PFC) Production schedule R&D

ISA 88 Physical Model Process Cell Unit Equipment Equipment Module Enterprise May contain Site May contain Area May contain Process Cell Must contain Unit Equipment May contain Equipment Module May contain May contain Control Module May contain

Equipment Entities -An Object Approach Physical Equipment Equipment Entities Instruments Basic control Coordination control Procedural control Equipment Control

Example of physical modeling Process Cell Unit Unit EM EM EM EM CM CM CM CM CM CM

Example of control modules CM4 CM2 D4 PID CM1 D3 D1 PID PID CM3 D5 D2 HIC HIC

Why Control Modules Treating as a control module simplifies the interface to this group of objects Commands Status Circulate Circulating Pump to Process Pumping to Process Stop Stopped FO Shutdown Shutdown FC Pump

Recipe/Equipment Control Separation Control Recipe Equipment Control Procedure Recipe Procedure Procedure [Must Always Exist] is an ordered set of Unit Procedure is an ordered set of Operation is an ordered set of Equipment Phase Phase

Recipe/Equipment Control Separation - Typical Control Recipe Equipment Control Procedure Recipe Procedure is an ordered set of Recipe Unit Procedure is an ordered set of Recipe Operation is an ordered set of Recipe References Equipment Phase Phase

Recipe/Equipment Control Separation - Alternate 3 Control Recipe Equipment Control Procedure References Recipe Equipment Procedure Procedure is an ordered set of Equip. Unit Procedure is an ordered set of Equipment Operation is an ordered set of Equipment Phase

Phase Interface Logic State machine enforcement between recipe phase and equipment phase A set of services that support commands to the equipment phase A set of services that support requests from the equipment phase to the recipe phase Phase Interface Logic Recipe Phase Equipment Phase 19

Phase Interface Logic Parameters Requests State States Commands Machine States Commands 21

Phase Object Parameters Data Start Run Hold Held Pause Paused Aborting Pausing Stop Stopped Abort Aborted Reset Idle Resume Holding Stopping Data Collection Requirements Completed Running Restart Restarting Control Action Status Control Steps

Example Procedural Element States Restart Complete Restarting Held Holding Reset Hold Idle Start Pause (Initial Running Pausing State) Resume Abort Stop Paused Aborting Stopping Final States Aborted Stopped Quiescent States Reset Transient States Reset

Exception Handling In Control Actions The safety interlock logic takes precedence over phase logic or process interlock logic. Typically this logic, when required, is implemented in an independent safety interlock system. Safety Interlock Control Module Exception Logic Process Interlock Control Module The process interlock logic takes precedence over phase logic and manual override logic. Typically, this logic is implemented in the DPCS. Phase Control step (command) Control Field I/O Logic Action Control Module/Control Equipment Module Action State/Mode Control Module Inhibit manual override (Interlock from phase logic), Also sent to console to inhibit Inputs to Control Action Logic: choice of manual mode - Set manual mode Console - Command from operator's console Control Control Module/Control Exception Logic Action State/Mode

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 material transfer Multiple levels of procedures Encapsulation (contents) of unit procedure revealed Provides more detail

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