NORMA ISA 95

Enterprise-Control System Integration Standard B2MML Business To Manufacturing Markup Language

Companies Participating in SP95

ABB Arla

Lund

Foods AspenTech Dupont Eli Lilly Emerson Process Management Fluor General Electric Invensys-Wonderware Lighthammer

University, Sweden Lyondell Equistar Microsoft Nestle Novo Nordisk Proctor & Gamble Purdue University Rockwell Automation SAP Siemens Yokogawa

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 integration Increase in business needs to integrate manufacturing sites with business systems Business drivers:

Supply chain optimization Asset efficiency Agile manufacturing Available to Promise & Available to Profit

What ISA-95 Offers

Framework for integration projects Separation of business processes from manufacturing processes Focus on functions, not systems, organizations or individuals

ISA-95 Scope

ENTERPRISE

95.01 & 2
SITE

95.03
AREA AREA AREA

CONTINUOUS PRODUCTION UNIT

BATCH PROCESS CELL

DISCRETE PRODUCTION LINE

5

Information of Interest
Functions Outside the Control Domain
(e.g. Production Scheduling)

Information Flows of interest

(e.g. Production Schedule and Production Results)

Enterprise/Control System Boundary

Functions detailed Functions not detailed Data flows detailed Data flows not detailed

Functions Within the Control Domain

(e.g. Equipment Monitoring)
6

Categories of Information

Business Planning & Logistics Information

Production Capability Production Definition

Resource Availability

Manufacturing Instructions, Recipes, BOM,

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

What was made and used

Manufacturing Operations & Control Information

7

Major Object Models

Three categories of resources

Personnel Equipment

Material (and Energy)

Process Segments Production Schedule

Combined resources (logical view)

Four Models / Production-Process-Product

Production Performance
Capability Definition (by time & by segment) Product Definition

Design 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

Definicin de Modelos

Necesidades de Importantes empresas del mundo

+
Experiencia de los Principales proveedores de soluciones tecnolgicas

=
Norma ISA 95

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

Scheduling and control hierarchy Level 4 Business Planning & Logistics

Plant Production Scheduling, Operational Management, etc

Interface addressed Parts 1 & 2

Level 3 Manufacturing Operations & Control

Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...

Area addressed Parts 3 & 4

Levels 2,1,0
Batch Control Continuous Control Discrete Control

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Equipment hierarchy model

ENTERPRISE

Enhanced in Part 3

Level 4 activities typically deal with these objects

SITE

AREA

Level 3 activities typically deal with these objects

PROCESS CELL

PRODUCTION UNIT

PRODUCTION LINE WORK CELL

STORAGE ZONE STORAGE MODULE

UNIT

Lower level equipment used in batch production

Lower level Lower level Lower level equipment used equipment used equipment used in continuous in repetitive or for storage production discrete production
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Functional data flow model

6
Functional data flow model

Reference Model
nd al a teri t a rs gm eip rde min gy rec O o c n r n I t io ene uc od it y r P bil ila a Av

Order Processing (1.0)

Finished Goods Inventory

Product Cost Accounting (8.0)

Product Shipping Admin (9.0)

Release to ship Confirm to ship

Material and Energy Control (4.0)

Pack Out Schedule Pr od Pr uc od t io uc t io n C Sc n he F r ap a du om bi le P la lit y n Short Term Material and Energy Requirements Production

Pe rfo Prod rm u an c tio Pr ce n od an u dc Ob c tio os jec n C t ti v os es t

Lon Ma g Te ter ial rm req ener g a nd ui r em y ent s

Production Scheduling (2.0)

Process Data

Fi d he nis s od Go W ve ai r

Material and Energy Inventory

Control (3.0)
Maintenance Standards and Methods Maintenance Requests

Procurement (5.0)
M Pu aint rc h en a Re q u as e nc e ire Or me de nts r

Quality Assurance (6.0)

Pro du P ct a Req roc es nd uire s me nts

Maintenance Management (10.0)

QA Re s ul

In Process Waiver Request Sta nd ar d Re s an qu d Pr ire C u o me s t o QA c es s nts me r Re Da ta su lt s

Product Inventory Control (7.0)

ts

May 2, 2006

in g om r Inc e Ord ation m n fir Co nd r al a teri r de Ma rgy O nts e e En uire m q Re

OAGi General Meeting ISA-95 - B2MML Briefing

w Ho now k t sK bac u es c es eed R eq Pr o al F ation nd ta nic duc ec h form s T s In Pro c es c es Pr o Pr o d nd t a t an duc duc Pro Maintenance Pro Technical Feedback Maintenance Responses

an d Re Cu ar d q u sto s ire me and m r en ts

St

Enterprise/ Control Boundary

Marketing & Sales

Research Development and Engineering

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Functional data flow model

7
Object Model

7.1 Categories of information 7.3 Production capability information

Identified Information Categories

Business planning & logistics information

Plant production scheduling, operational management, etc

Product Production Production Production definition capability response schedule information information information information
(What must be defined to make a product) (What resources are available) (What to make and use)

(What was made and used)

Manufacturing operations & control information

Production operations, maintenance operations, quality operations, etc

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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

Personnel Model

Personnel Class

0..n 0..n Defined by

Person

Has Properties of 0..n

Has values for

0..n Maps to

Personnel Class Property

Is tested by a 1..n

Person Property
0..n

0..n

Qualification Test Specification

0..n Defines a procedure for obtaining a Records the execution of

Qualification Test Result

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Persons and Personnel Classes

Supervisor Professional Laborer Engineer

Operator

Pump Draftsman Mechanic

Qualification Test

Sally Jones- ID#12344

Joe Smith - ID#12345

Qualification Test Results

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Equipment model

Is against May be made up of 0..n 0..n

Maintenance Request
0..n May result in

Equipment Class
Has Properties of

0..n 0..n Defined by

1..1

Equipment
1..1 0..n Is made against 0..1

Has values for

Maintenance Work Order

1..1

0..n

0..n Maps to

0..n

May be generated for

Equipment Class Property

Is tested by a 1..n 0..n

Equipment Property
0..n

Maintenance Response Equipment Capability Test Result

Equipment Capability Test Specification

0..n Defines a procedure for obtaining a

Records the execution of

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Equipment and Classes

Heating Reactor

Mixing Reactor

Maintenance Request

Capability Test

Maintenance Work Order

HR101

HR102

HMR101

MR101

MR102 Capability Test Results

Max Temp = 300 F

Capacity = 5000 Gal

Shearing = TRUE

Capacity = 3000 Gal

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Material model

Material Class

Defines a grouping 0..n 0..n

Material Definition

0..n 1..1 Defined by

Material Lot

Made up of 0..n

Material Sublot
0..n

Has Properties of 0..n

Has Properties of 0..n

Has values for

May be made up of sublots

0..n Maps to

Material Class Property

May map to

Material Definition Property

Is tested by a 1..n

Material Lot Property

0..n Records the execution of Is associated with a

0..n

QA Test Specification

0..n Defines a procedure for obtaining a

QA Test Result

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Material Definition Example

Material Class HCl Acid

Material Definition HCl 50%

Lot HCL-50-100019

Sublot HCL-50-100019 Barrel 15

pH

Density

Color Purity

QA Test Results

Location QA Test Specification

pH 1.0

Density Color Purity 1.05 Straw 99.5%

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Process Segment Model

Personnel resources managed for production
People

Equipment resources managed for production

Equipment

Material resources managed for production

Materials

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

Process Segments
Business view of production

Pharmaceutical Manufacturing
(3 Segments)
Make Active Ingredient Make Pills Package Doses

Raw Materials

Finished Products

Inventory tracked for Active Ingredient Know throughput, resources and time to make Active Ingredient

Inventory tracked for Pills

Inventory tracked for Pill Packs

Know throughput, resources and time to make Pills

Know throughput, resources and time to make Pill Packs

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7.4 Product definition information

7.5 Production information

7.5.1 Production Schedule Model 7.5.2 Production Performance Model

Production, Capability, Product

What to make and resources to use

Production Schedule

What was made and resources actually used

Production Performance

What is available for use for production

Product

Time

Capability/Capacity

What is needed to make a product

Product Definitions
39

Production Schedule

People

Equipment

Product Definitions

Materials

Production Schedule

Segments
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7.5 Production Schedule Model

Production Schedule
Is made up of Corresponds to a 1..n

Product Production Rule

Production Request

Is made up of 1..n 0..n

Process Segment

Corresponds to a

Segment Requirement
May contain

Requested Segment Response

0..n

0..n

0..n

0..n

0..n

0..n

Production Parameter
Is associated to either

Personnel Requirement

Equipment Requirement

Material Produced Requirement

Material Consumed Requirement

Consumable Expected

1..n

1..n

1..n

1..n

1..n

Personnel Requirement Property Product Parameter

Corresponds to element in

Equipment Requirement Property

Material Produced Requirement Property

Material Consumed Requirement Property

Corresponds to element in

Consumable Expected Property

Corresponds to element in

Corresponds to element in

Process Parameter

Personnel Model

Equipment Model

Material Model

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Production Performance

People

Equipment

Product Definitions

Materials

Production Schedule

Segments

Production Performance
42

7.5 Production Performance Model

Production Performance
Is made up of 1..n

Production Response
Is made up of 1..n Corresponds to a

Process Segment

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

Corresponds to element in

Equipment Actual Property

Corresponds to element in

Material Produced Actual Property

Material Consumed Actual Property

Corresponds to element in

Consumable Actual Property

Corresponds to element in

Personnel Model

Equipment Model

Material Model

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Resumen

Production Schedule Application

Multiple levels of planning & scheduling

Quarterly Monthly Weekly Dispatch to Production

ISA-95 Production Schedule

Dispatching

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

Setpoints & Flowpaths

Batch Schedule

Setup Instructions

Continuous Premix

Batch Production Process

Discrete Packaging

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ISA-95 Functional Hierarchy

Level 4

Business Planning & Logistics

Plant Production Scheduling, Operational Management, etc

Level 3

Manufacturing Operations & Control

Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...

Parts 1, 2 & 5 focus on this Interface

Levels 2,1,0

Parts 3 & 4 Focus on Manufacturing Operations

Batch Control

Continuous Control

Discrete Control

May 2, 2006

OAGi General Meeting ISA-95 - B2MML Briefing

46

ISA-95 Part 3 Generic Model

Operations definitions Operations capability Operations request Operations response

Detailed scheduling Resource management

Tracking

Dispatching

Analysis

Definition management Execution management

Data collection

May 2, 2006

OAGi General Meeting ISA-95 - B2MML Briefing

47

4 Sets of Level 3 Activities

Production Management
Detailed scheduling resource management dispatching definition management execution management data collection tracking performance analysis definition management execution management resource management dispatching data collection Detailed scheduling tracking performance analysis

Resourse Management

Detailed scheduling resource management dispatching definition management execution management data collection tracking performance analysis definition management resource management

Detailed scheduling tracking dispatching data collection execution management performance analysis

Inventory Management

Quality Management
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