1. Beyond Production with ISA95/B2MML
SP95 started with an exclusive focus on production, ignoring many side aspects of manufacturing. Maintenance and quality were roughly addressed at the resource level, warehouse operations weren't even mentioned.
Part 3 ended up with an activity model template that the standard recommends applying to 4 domains: Production, Maintenance, Quality and Inventory. This overpasses part 1 scope and almost conflicts with its models.
As ISA95 gains recognition we become confronted with actual implementation issues were "side" manufacturing activities and logistics represent a significant part of the cost and time involved in the final product, thus resource usage and business to manufacturing (execution) information flows.
The presentation will show the use of the designed-for-flexibility ISA95 data models to cover the needs of structuring B2M interface for most types of shop floor activity.
Jean Vieille conseil
20/07/2004

2. Presenter
Experience
Process control, Production/ERP integration, Finite capacity scheduling, MES, LIMS, historians.
Industries: Pulp & paper, textile, wood, metallurgy, chemical, pharmaceutical, food & beverage, electronics…
Consulting with final users, solution providers, integrators and academics
Technical awareness, volunteer organizations
Member of ISA SP88 Batch Control Systems and SP95 Enterprise-Control System Integration,
ISA District 12 Vice president ISA France section president,
Member of APICS, World Batch Forum “Flow Analysis” WG chair, French Batch Forum founder

3. Agenda ISA95 history status and future ISA95 dicrepancies
Tentative generic ISA95 data models
Other ISA95 issues
B2MML
Application to inventory operations
Conclusion

4. ISA95 start The story started from SP88
ISA88 had to reduce its wide initial scope
SP95 started at ISA88 part one completion
Initially focused on
Process industry : SP88 members background)
Production only : maintenance and quality not considered as specific activities
Part 1 issued in 2000
Data models
Part 2 issued in 2001
Adding attributes on part 1 models
Part 1 and 2 should have been merged in IEC/ISO 62264, but have been kept separated for consistency with SP95 work
B2MML first draft issued in 2000, V02 09/2003
compliant with part 1/2

5. ISA95 Part 3 spontaneous generation
What’s inside the manufacturing / execution domain was unclear
Needed to define more clearly the MES / Control system fuzzy area
Part 3 defined first a production operation management functional model
Maintenance and quality appeared to be manufacturing operation categories (MOC) on their own, then inventory, then…
Inbound logistics, Outbound logistics
Internal transfers, Inventory checks
Cleaning
Tooling
Cafeteria, Fire dpt, Infirmary…

6. Part 3 multi-MOC functional model
Level 2
Maintenance
Production
Quality
Inventory X
collection
data
execution
resource
management
dispatching
tracking
performance
Detailed
production
scheduling
schedule
Product
definition
analysis
capability
response
Detailed maintenance
request
definitions
Detailed inventory
test resource
Quality test
Detailed quality test
test data

7. ISA 95 Part 3 status Part 3 tri-dimensional model proposes
a generic model for executing any kind of “Work”
applying to each manufacturing operation management category
Implying shared functions between manufacturing operation categories
Including shared supporting functions
Part 3 is already remarkably adopted before being published
A consistent framework for MES URS
Draft 17 June 2004

8. ISA95 next items Part 4: data model extensions Not formally decided
Part 5: Transactions
First draft available

9. Agenda ISA95 history status and future ISA95 dicrepancies
Tentative generic ISA95 data models
Other ISA95 issues
B2MML
Application to inventory operations
Conclusion

10. Part 1/2 and B2MML no longer consistent, hardly relevant
Part 1/2 models are « production » flavoured
They include maintenance activity as an appendix of equipment model
Simplistic model
Inconsistent with part 3
Part 1 / 2 not addressing actual integration needs
Business / Execution integration needs go beyond production restricted information
They do not handle other manufacturing operation categories
Inventory

11. Part 3 acknowledge Part 1 data model extensions
Schedule/Request information
Performance/Response information
Production
schedule
Maintenance
schedule
Quality Test
schedule
Inventory
schedule
Production
performance
Maintenance
response
Quality test
response
Inventory
response
Manufacturing
operations
Production
operations
management
Maintenance
operations
management
Quality
operations
management
Inventory
operations
management
Product
definition
information
Maintenance
definition
information
Quality test
definition
information
Inventory
definition
information
Production
capability
Maintenance
capability
Quality Test
capability
Inventory
capability
Definition information
Capability information

12. Agenda ISA95 history status and future ISA95 dicrepancies
Tentative generic ISA95 data models
Other ISA95 issues
B2MML
Application to inventory operations
Conclusion

13. Tentative generic ISA95 data models
Part 1 / 2 models were developped by only considering production issue
However,
they are very flexible
Resource models are generic be essence
Firemen and operators just have different skills
Any work is driven by schedule
Taking care of exceptions (equipment breakdown, urgent order, fire in a fool reactor…)
Any work has to follow rules and specific instructions and procedures
Proceeding with an analysis, making a batch, sharpening a tool

14. Proposed part 1 revision
Define a generic data model
Based on the current production related data model
Providing a set of standard generic, MOC independent attributes
Apply this model to the for manufacturing operation categories defined in part 3 as examples
Production, Maintenance, Quality, Inventory
Providing a set of standard MOC specific attributes
Provide guidances for consistent and compliant usage of the models
Join part 1 & 2
Each work element is MOC stamped
MOCs can be potentially mixed:
A work schedule may contain production, inventory, and quality process segments
Align B2MML on this new ontology

15. Proposed generalized Terminology
Process = Process
Product = Work
Production = Working
Material consummed = Material In
Material produced = Material out

16. Resource models: unchanged
Personnel, Material, Equipment are essentially independent of the operation categories
Maintenance wart on equipment model is deprecated
Maintenance
Request
< May be made up of
◄ Is against
0..n
1..1
0..n
Equipment
Class
Equipment
0..n
May result in >
0..n
0..n
Defined by <
0..1
1..1
0..n
Maintenance
Work Order
Has
properties
of >
Has
values for >
Is made
against <
1..1
0..n
May be generated for >
0..n
0..n
Maintenance
Response
Equipment
Class Property
Equipment
Property
Maps to
Is tested
by a >
1..n
0..n
Equipment
Capability Test
Result
Equipment
Capability Test
Specification
0..n
0..n
Records the
execution of >
Defines a
procedure for
obtaining a >

17. Process segment: unchanged
A type of consolidated resource
Stays unchanged, implying modularized « processing requirement » for any kind of work
0..n
0..n
has an execution dependency on
May be
made up of
Process
Segment
0..n
Process
Segment
Dependency
is a collection of
0..n
0..n
0..n
0..n
Personnel
Segment
Specification
Equipment
Segment
Specification
Material
Segment
Specification
Process
Segment
Parameter
Has properties of
Has properties of
Has properties of
0..n
0..n
0..n
Personnel Segment SpecificationProperty
Equipment Segment SpecificationProperty
Material Segment
SpecificationProperty
0..n
Corresponds
to element in
0..n
Corresponds
to element in
0..n
Corresponds
to element in
Personnel
Model
1..1
Equipment
Model
1..1
Material
Model
1..1

18. Process segment capability: unchanged
Stays Process Segment Capability, implying modularized « processing capability » for any kind of work
Process
Segment Capability
Process
Segment
Corresponds to
Is a collection of
0..n
0..n
0..n
Personnel
Segment
Capability
Equipment
Segment
Capability
Material
Segment
Capability
Has properties of
Has properties of
Has properties of
0..n
0..n
0..n
Personnel
Segment
Capability Property
Equipment
Segment
Capability Property
Material
Segment
Capability Property
0..n
Corresponds
to element in
0..n
Corresponds
to element in
0..n
Corresponds
to element in
Personnel
Model
1..1
Equipment
Model
1..1
Material
Model
1..1

19. Production Capability => Work Capability
Production changed by « Working »
Production
Capability
Working
Capability
Is a
collection of
Is a
collection of 1 1
0..n
0..n
0..n
0..n
0..n
0..n
0..n
0..n
Personnel
Capability
Equipment
Capability
Material
Capability
Process
Segment
Capability
Personnel
Capability
Equipment
Capability
Material
Capability
Process
Segment
Capability
Has properties of
Has properties of
Has properties of
Has properties of
Has properties of
Has properties of 1 1 1 1 1 1
0..n
0..n
0..n
0..n
0..n
0..n
Personnel
Capability
Property
Equipment
Capability
Property
Material
Capability
Property
Personnel
Capability
Property
Equipment
Capability
Property
Material
Capability
Property
0..n
Corresponds
to element in
0..n
Corresponds
to element in
0..n
Corresponds
to element in
0..n
Corresponds
to element in
0..n
Corresponds
to element in
0..n
Corresponds
to element in
Personnel
Model
1..1
Equipment
Model
1..1
Material
Model
1..1
Personnel
Model
1..1
Equipment
Model
1..1
Material
Model
1..1

20. Product definition: clarification needed
Has a reference to >
Has a reference to <
Has a reference to >
Bill of
Resources
(External)
Product
Production Rule
(External)
Bill of
Material
(External)
Need of complex relationships with BOR, BOM, Product production rules to be challenged
Product
Definition
Has
associated >
Has
associated
Has
associated >
Has
associated >
May be
made
up of
0..n
1..n
Corresponds to
0..n
0..n
Product
Segment
Process
Segment
Manufacturing
Bill
has an execution dependency on
0..n
0..n
0..n
1..n
0..n
1..1
Product
Segment
Dependency
Is a collection of
0..n
0..n
0..n
0..n
1..n
Product
Parameter
Personnel
Specification
Equipment
Specification
Material
Specification
0..n
0..n
0..n
Personnel
Specification
Property
Equipment
Specification
Property
Material
Specification
Property
0..n
Corresponds
to element in
0..n
Corresponds
to element in
0..n
Corresponds
to element in
Personnel
Model
1..1
Equipment
Model
1..1
Material
Model
1..1

21. Becomes Work definition
Potential links with other business related entities as optionnal attributes
BOM
BOR
PPR
Manufacturing bill
As they are in B2MML
Or have a production definition derived from the generic Work definition model
Has
associated
May be
made
up of
0..n
1..n
Corresponds to
Work
Segment
Process
Segment
has an execution dependency on
0..n
0..n
0..n
1..n
0..n
Work
Segment
Dependency
Is a collection of
0..n
0..n
0..n
0..n
Work
Parameter
Personnel
Specification
Equipment
Specification
Material
Specification
0..n
0..n
0..n
Personnel
Specification
Property
Equipment
Specification
Property
Material
Specification
Property
0..n
Corresponds
to element in
0..n
Corresponds
to element in
0..n
Corresponds
to element in
Personnel
Model
1..1
Equipment
Model
1..1
Material
Model
1..1

22. Production schedule =>
Is made up of
Product
Production
Rule
1..n
Corresponds
to a <
Production
Request
Is made up of
1..n
0..n
Process or
Product
Segment
Corresponds
to a <
Segment
Requirement
Requested
Segment
Response
May contain
0..n
0..n
0..n
0..n
0..n
0..n
Production
Parameter
Personnel
Requirement
Equipment
Requirement
Material
Produced
Requirement
Material
Consumed
Requirement
Consumable
Expected
Is associated
to either >
Note: the current single link between Production Request and Product Production Rules seems wrong.
It should be « Product Definition » at least (PPR may be an additional link)
1..n
1..n
1..n
1..n
1..n
Personnel
Requirement
Property
Equipment
Requirement
Property
Material Produced
Requirement
Property
Material Consumed
Requirement
Property
Consumable
Expected
Property
Product
Parameter
Process
Parameter
Corresponds to
element in
Corresponds to
element in
Corresponds to
element in
Corresponds to
element in
Personnel
Model
Equipment
Model
Material
Model

23. …=> Work Schedule Working Schedule Work Definition Working Request
Is made up of
1..n
Work
Definition
Corresponds
to a <
Working
Request
Is made up of
1..n
0..n
Process or
Work
Segment
Corresponds
to a <
Segment
Requirement
Requested
Segment
Response
May contain
0..n
0..n
0..n
0..n
0..n
0..n
Working
Parameter
Personnel
Requirement
Equipment
Requirement
Material
Produced
Requirement
Material
Consumed
Requirement
Consumable
Expected
Is associated
to either >
1..n
1..n
1..n
1..n
1..n
Personnel
Requirement
Property
Equipment
Requirement
Property
Material Out
Requirement
Property
Material In
Requirement
Property
Consumable
Expected
Property
Work
Parameter
Process
Parameter
Corresponds to
element in
Corresponds to
element in
Corresponds to
element in
Corresponds to
element in
Personnel
Model
Equipment
Model
Material
Model

24. Production Performance =>
Is made up of
1..n
Production
Response
Is made up of
1..n
Process
Segment
Corresponds
to a <
Segment
Response
May contain
0..n
0..n
0..n
0..n
0..n
0..n
Production
Data
Personnel
Actual
Equipment
Actual
Material Produced
Actual
Material Consumed
Actual
Consumable
Actual
1..n
1..n
1..n
1..n
1..n
Personnel
Actual
Property
Equipment
Actual
Property
Material Produced
Actual
Property
Material Consumed
Actual
Property
Consumable
Actual
Property
Corresponds to
element in
Corresponds to
element in
Corresponds to
element in
Corresponds to
element in
Personnel
Model
Equipment
Model
Material
Model

25. …=> Work Performance
Working
Performance
Is made up of
1..n
Working
Response
Is made up of
1..n
Process
Segment
Corresponds
to a <
Segment
Response
May contain
0..n
0..n
0..n
0..n
0..n
0..n
Working
Data
Personnel
Actual
Equipment
Actual
Material Produced
Actual
Material Consumed
Actual
Consumable
Actual
1..n
1..n
1..n
1..n
1..n
Personnel
Actual
Property
Equipment
Actual
Property
Material Out
Actual
Property
Material In
Actual
Property
Consumable
Actual
Property
Corresponds to
element in
Corresponds to
element in
Corresponds to
element in
Corresponds to
element in
Personnel
Model
Equipment
Model
Material
Model

26. Model Instanciation The models apply as is for any MOC
However, attributes depend on:
MOC specifics
Production, inventory, quality, maintenance
Transaction specifics
Intermediate or final reporting
Industry specifics (i.e Food & Beverage)
Expiration date applies for perishable goods
Solution specifics (i.e. SAP)
ReverseTransaction
User specifics (i.e. P&G, Nestlé…)
GTIN

27. Agenda ISA95 history status and future ISA95 dicrepancies
Tentative generic ISA95 data models
Other ISA95 issues
B2MML
Application to inventory operations
Conclusion

28. Align material resource specification and usage
Material in / out and material consummed for
Process segment
Process segment capability
Working capability
Work definition / Work segment
As it is in
Production schedule
Production performance
Personnel
Requirement
Equipment
Material
Produced
May contain
0..n
1..n
Production
Schedule
Consumed
Consumable
Expected
Segment
Is made up of
Parameter
Request
Personnel
Segment
Capability
Equipment
Material
Process
Segment Capability
Is a collection of
0..n

29. Process / product / Production segment recursivity
Process segment capability
in Working capability and process segment capability
Segment requirement
in production schedule (OK In B2MML)
Segment response
in production performance (OK In B2MML)
Production
Capability
Production
Request
Production
Response
0..n
0..n
0..n
1..n
1..n
Process
Segment
Product
Segment
Process
Segment Capability
Process
Segment
Capability
Segment
Requirement
Segment
Response
0..n
0..n

30. Agenda ISA95 history status and future ISA95 dicrepancies
Tentative generic ISA95 data models
Other ISA95 issues
B2MML
Application to inventory operations
Conclusion

31. B2MML
B2MML schemas will be easily aligned to the generalized ISA95 part 1 models
Extension mechanisms must be improved / complemented
Properties
User defined extensions in separate files/namespaces
They shall provide
a basic set of generic referenced schemas
a serie of standard/custom extensions schemas for MOC / Transactions / Industry / Solution / User specifics
A template for generating schemas instances

32. B2MML
Example: WorkSchedule

33. Agenda ISA95 history status and future ISA95 dicrepancies
Tentative generic ISA95 data models
Other ISA95 issues
B2MML
Application to inventory operations
Conclusion

34. Example: Work schedule for transfer orders
Simplifed Working schedule
Working
Schedule
Is made up of
1..n
Working
Request
Is made up of
1..n
Segment
Requirement
May contain
0..n
0..n
Material In
Requirement
Material
Out
Requirement

35. Example: transfer order
Dispatch production run ##
Transfer Schedule
Transfer Request
2nd lading mission
1st lading mission
Segment Requirement
Segment Requirement
Personnel Requirement
Equipment Requirement
Items a, b, c
(loc X1)
item a (QC area)
Items b, c (loc Y1)
99Kg Mat A (LocY2)
1Kg scrap
100kg Mat A (loc X1)
Material In Requirement
Material Out Requirement
Material In Requirement
Material Out Requirement

36. Transfer transaction examples (from Nestlé)
Transfer schedule:
Storage location to Storage location
Transfer performance:
Storage location to Storage location (sollicited)
Confirm transfer
Cancel transfer
Storage location to Storage location (unsollicited)
Inbound receipt
Sublot transfer
Plant to Plant
Batch to Batch
Material status change

37. Agenda ISA95 history status and future ISA95 dicrepancies
Tentative generic ISA95 data models
Other ISA95 issues
B2MML
Application to inventory operations
Conclusion

38. 7. Conclusion MOC part 3 concept shall be introduced in part 1
High priority item
May delay part 4 and 5
Part 1 data models can be (very) easily generalized
to allow their application to any MOC
They need some improvements based on
B2MML development and implementation feedback
Generalized needs from MOC instantiation
Next B2MML release candidate
Can implement and validate modified generic models
Can be developed on the spot – Drafts already available

39. Thank You