1. 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

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

3. ISA 88 and 95 in SCM and Production Scheduling

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

5. 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

6. 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 / 02
Manufacturing
Operations Support
(MES)
dS95.03 Area
S88
Source: ISA dS95.01 Enterprise/Control System Integration

7. 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

8. 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

9. 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

10. 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

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

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

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

14. ISA 95 : Enterprise – Production Communication

15. What is ISA95 ? Status SP95 committee started in October 1996
ANSI/ISA available from ISA
Submitted to IEC/ISO
Joint Working Group (JWG 15) to be established
ISA in draft, out for vote
Out for committee ballot and public comment
ISA in draft
Still under development in the committee
World Batch Forum
Developing XML Schemas for the exchanged information

16. 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

17. 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

18. 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

19. 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

20. 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

21. 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 Copyright ISA Used with permission.

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

23. 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

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

25. 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

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

27. 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

28. 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

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

30. 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

31. Production Schedule People Equipment Product Definitions Materials
Segments

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

33. 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

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

35. 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

36. 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

37. ISA 88 : Modular control

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

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

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

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

42. 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

43. 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

44. 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 (PFC)
Production schedule
R&D

45. 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

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

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

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

49. 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

50. 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

51. 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

52. 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

53. 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

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

55. 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

56. 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

57. 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

58. 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

59. THANK YOU