aS TECHNISCHE eT Dla) ISA 95 & IEC/ISO 62264 (based on a talk by D.Brandl & P.OWen) VL Prozessrechen- und -leittechnik Professur fur ProzessleittechnikTECHNISCHE ) UNIVERSITAT DRESDEN Manufacturing in the Supply Chain « “Make” is a significant part of the supply chain and collaborative manufacturing, but is often the last element to be actually integrated - Collaboration in “Make” is usually not a “Low Hanging Fruit” - But can offer very high ROI for high volume, or high cost products However, Business IT and Manufacturing IT organizations are often at odds as they try to collaborate - They have different goals and different success criteria - They use the same terms for different elements and different terms for the same elements Prasentationsname XYZ Folie 2 von XYZTECHNISCHE ) UNIVERSITAT DRESDEN Different Points of View Business Systems Manufacturing Systems ime Horizons Time Horizons ~Long-term view -Real-time view *Model detail *Model detail ~Linear route structures Complex routes with rework *Control emphasis paths -Product cost and overall Control emphasi profitability on cmpnasis ‘Modeling criteria: -Physical movement & Accounting reference points accountability -Has inventory value changed *Modeling criteria: significantly? If not, don’t model ~material movement reference separately points View from the boardroom Does product stop moving? If not, don’t model separately View from the workcenter Prisentationsname XYZ Folle 3 von XYZTECHNISCHE © UNIVERSITAT DRESDEN Philosophical Orientation Enterprise Management systems: How much is my stuff worth? Manufacturing Operations Systems: Where is my stuff? Prasentationsname XYZ Folie 4 von XYZTECHNISCHE © UNIVERSITAT DRESDEN ISA 95 Provides Direction ANSI/ISA 95.00.01-2000 “Enterprise - Control System Integration - Part 1: Models and Terminology” = Draft DIN EN IEC/ISO 62264-1 ANSI/ISA 95.00.02-2001 “Enterprise - Control System Integration - Part 2: Object Attributes” = Draft DIN EN IEC/ISO 62264-2 Draft ISA 95.00.03 “Enterprise - Control System Integration - Part 3: Activity Models of Manufacturing Operations Management” = Draft DIN EN 62264-3 Prasentationsname XYZ Folie 5 von XYZTECHNISCHE © UNIVERSITAT DRESDEN ISA95.01 Levels Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Interface addressed in the ISA 95.01 and Level 3 ISA 95.02 standard ) addressed Manufacturing Operations & Control in, Detailed Productior As in the ISA 95.03 standard Discrete ControlTECHNISCHE ) UNIVERSITAT DRESDEN ISA95. Pa deve! Ss Interface addre in the ISA 95.01 ISA 95.02 stanc N a . Area addresset Operations & Contro in the ISA 95.0: standard Level 3ome ISA 95 Part 1 and Part 2 Exchanged Information Information that crosses the boundary between business systems and manufacturing systemsTECHNISCHE © UNIVERSITAT DRESDEN CFP RET alacor Sein Operational Management, etc Manufacturing Control Information Area Supervision, Production Planning, Reliability, Assurance, etc Folie 9 von XYZTECHNISCHE © UNIVERSITAT DRESDEN 4x4 Object Models Four categories of resources - Personnel - Equipment - Material (and Energy) —- Process Segments Four Process, Product, & Production Models - Capability & Capacity Definition - Product Definition - Production Schedule - Production Performance Prasentationsname XYZ Folie 10 von XYZTECHNISCHE © UNIVERSITAT DRESDEN Four e Object Models +— Personnel resources managed for production People g <—— Equipment resources managed for production Tquipment ew +— Material resources managed for production 4 +— Business view of production processes Process Segments Prasentationsname XYZ Folie 11 von XYZTECHNISCHE © UNIVERSITAT DRESDEN Capability, Product, Schedule, and Performance Informption-...---- +— Whatis available for use for production Time Capability/Capacity +— What is needed to make a product Product Definitions be <— What to make and resources to use Production Schedule es <+— What was made and resources actually used Production Performance PrasentationsnéTECHNISCHE UNIVERSITAT DRESDEN + Production Schedule +Production Request juest than Set EUES Broducea Material Ee dates + Expected Consumed Material | _ what materials to use + Expected Personnel ~ What equipment to use * Expected Equipment ~ What personnel to use| Production Parameters ~ Production paramete (e.g. Color, Options... People Materials Production Schedule Per location (Site, Area, ...] Per week, day, shift, order, ... ) SegmentsTECHNISCHE UNIVERSITAT DRESDEN + Production Performance +Production Response (on Pere ieee Actual + Consumed Material Actual + Personnel Actual + Equipment Actual + Production Data Equipment Materials e i Production 9 praceerformance,, What was made ~ What material was actually produced - What materials were actually consumed - Equipment used ~ Personnel used ~ Production data (e.g. Purity, density... gm Per location (Site, Area, .. Per shift hour, end of batch...TECHNISCHE ) UNIVERSITAT DRESDEN XML Standard for B2M Exchanges * The World Batch Forum has developed XML Schemas that map to the ANSI/ISA-95 models * Defines how to represent the ISA-95 information in XML - Business To Manufacturing Markup Language = B2MML * One schema for each object model * Formal way to exchange information - www.wbf.org Prasentationsname XYZ Folie 15 von XYZTECHNISCHE © UNIVERSITAT DRESDEN An XML Example - Material Lot Material ‘ W89 A lot of material WXB9O8 Tank 1 4500

dateTimeProduction 2001-01-06T00:14:23+11:30 Quality Status Good Prasentationsname XYZ Folie 16 von XYZaS TECHNISCHE eT Dla) ISA95 Part 3 Activity Models of Manufacturing Operations In Development Expected Release 2004TECHNISCHE UNIVERSITAT DRESDEN Production aes Scheduling ER ; (2.0) Material and Energy Control (4.0) Procurement (5.0) Processing Order Product Cost Accounting Production Control Quality Assurance Research Development and Engineer ‘Maintenance Management (10.0) Product Shipping Admin (80)TECHNISCHE UNIVERSI DRESDEN, i P i P i ISA 96.03 Manufacturing Equipment and Process ‘Specific Production Rules Operational Commands, Equipment and Process Specific Data Level 2 Process Control Prasentationsname XZ Folie 19 von XYZTECHNISCHE ) UNIVERSITAT DRESDEN Other Enterprise Activities in Manufacturing Operations Some actives are not sbEME te manutal ISA-95.03 lists references to standards Inventory Major |Level 3 Operations Activities Within Manufacturing Operations Level 2 D nativity setaites ADD hctvity not detated activity outside scopd Prasentationsname XYZ Folie 20 von XYZTECHNISCHE ) UNIVERSITAT DRESDEN Building Collaborative Manufacturing Systems Process Used to Develop Solution Architectures - Conceptual Topology - Functional Areas - Standards and Guidelines - Standard Applications - Logical Architecture Design — Physical Architecture Design Prasentationsname XYZ Folie 21 von XYZTECHNISCHE UNIVERSITAT DRESDEN Business Logistics ISA-IECIISO Plant Production Scheduling, Shipping, Interface Receiving, Inventory, etc ‘Standards: ISA. . Functional Manufacturing Level 3 Operations Management Dispatching, Detailed Production IEC, OPC, & Scheduling, Production Tracking, ... OMAC Interface ‘Standards: Level 2 Prasentationsname XYZ Folie 22 von XYZTECHNISCHE © UNIVERSITAT DRESDEN Conceptual Topology — IT View «IT View of the ISA-95 Levels and relationship to systems and networks * Levels 1-2 - Control the process and provide visibility to the process - Electronic records are not embedded in the control layers (Level — Usually some specialized hardware and possibly networks ° Level 3 - Maintenance of production information is centralized to provide greater control and availability of the records - Electronic records are managed and controlled through Level 3 systems with audit trail, access control, backup, and ERP connectivity - Usually standard hardware and networks Prasentationsname XYZ Folie 23 von XYZTECHNISCHE UNIVERSITAT DRESDEN “Level 4 Core Logistics Systems MES, LIMS, WMS, Level 3 SSS SCCM Systems Level 2 HMI, SCADA, ESET Batch Systems PLC, DCS, Packaged Systems W/O, Devices, g . : SensorsTECHNISCHE ) UNIVERSITAT DRESDEN Functional Areas * Use the ISA 95 and ISA 88 models of functions * Map the functions to system areas and networks * Use the ISA 95 rules for determining what is in Level 3 (vs Level 4) - The function is critical to maintaining regulatory compliance. * Includes such factors as safety, cGMP, and environmental compliance - The function is critical to plant safety - The function is critical to product quality - The function is critical to plant reliability Prasentationsname XYZ Folie 25 von XYZTECHNISCHE ) UNIVERSITAT DRESDEN Business Process Information Network Detailed Scheduling Production Tracking Product Definition Management) (Production Dispatching) Production Execution {Configuration Managemen’) (Production Analysis) Meese en eo Level 2 Recipe Contra} Gupervisory Contra) Cperatr Conte) Operator Visibility) — Equipment information Collection Automation Network ©n/Off Control) (Continuous Control) (Phase Contro) Programmed Contra) (nterlock & Safety Conta) Discrete & Process Device Communication Networks Level 1 ‘Manipulate Equipment) (Manipulate Process) Prasentationsname XYZ Folie 26 von XYZTECHNISCHE © UNIVERSITAT DRESDEN Logical Architecture * Maps functional areas and data locations Independent of technology * Defines the different layers of the architecture in terms of data and control These are mapped to physical networks, servers, and applications in the physical architecture * Defines what functions are to be performed at each level, and what data is to be maintained at each level To result in maintainable and robust systems To provide a way to manage the life cycle of the production systems Provides the structure required to grow and modify the system without compromising any of the previous advantages Prasentationsname XYZ Folie 27 von XYZ@ TECHNISCHE UNIVERSITAT Operator Control Batch Execution Realtime Data and Buffering Real-time Control and Data Collection Repo! ing HMI|/Engineering Tools| Site Data Storage ERP Connection Area Data Storagel]| MES | Supervisory HMI | [Recipe Execution| Level 2 Data Acquisition Operations Information Network Automation Network Controller |} Packaged Equipment Sensors/Actuators Device Connection & /Networks Process/Equipment Level 1TECHNISCHE ) UNIVERSITAT DRESDEN A Physical Architecture « Defines the IT infrastructure and applications - Defines networks and network connections - Defines locations of applications - Defines locations of servers - Defines the mapping of applications to servers e Physical architecture depends on the solution set used: - Vendor capabilities - Networks - Security and network management Prasentationsname XYZ Folie 29 von XYZTECHNISCHE UNIVERSITAT DRESDEN Patabase Level 3 Patsbasd Ea Doman Chr i Ea DN} {Connection| Physica Site ysica eee GU informa SUN [Eeverrecvalll Nebore Enos = VLAN [Configuration] MES: ag Tool Domain Chl Switch Server Server Soe Woe coer Area Operations Information Network I Ethernet MTS a a Level 2 Collection Viewer Execution Gar] One Instance Per Process Cell Automation Network Thanet Management |[ PLC ]{ DCS ][Embedded PC][ Packaged Equip] Leyel 1TECHNISCHE © UNIVERSITAT DRESDEN Conclusions e Linked execution systems deliver results! - Reduced direct costs; increased productivity - Improved traceability; reduced “witch hunt” expense - Near-theoretical cycle times: customer responsiveness, reduced WIP inventory - Greater agility: smaller lot sizes, more premium products in the mix, happier customers, happier shareholders! ¢ S95 defines the currency for manufacturing object and information exchange - Faster project implementation cycles - Flexibility to integrate and realign as corporate structures change Prasentationsname XYZ Folie 31 von XYZTECHNISCHE ) UNIVERSITAT DRESDEN Literatur ISAQS aka IEC/ISO 62264 World Batch Forum: www.wbf.org Developed XML Schemas for the exchanged information Prasentationsname XYZ Folie 32 von XYZ