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1SA95 Standards - Practical

Application Manufacturing
Paul Ashmore,
GE Fanuc Automation

©) GE Fanuc Automation
Printed and published by the IET, Michael Faraday House, Six Hills Way,
Stevenage, Herts SG1 2AY, UK

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With ever-increasing competitiveness and globalization, innovative manufacturers are adapting
and optimizing their methods to the 21st Century "pull" markets. One of the biggest challenges of
this is the integration of the various business systems. GE Fanuc are actively involved in the
development and implementation of the ISA95 standards to address this area, integrating across the
Enterprise.

About your speaker

Paul Ashmore has more than 25 years experience of working with Automation systems within the
Manufacturing Enterprise, from Automatic Test Equipment (ATE) through to Supervisory Control
and Data Acquisition (SCADA) to Manufacturing Execution Systems (MES).
During this time he has worked with such companies as IBM, Teradyne and UGS (formerly
USDATA) as well as being an active committee member of the European MESA organisation.
Currently a Commercial Engineer with GE Fanuc Automation Europe and actively involved in
Consultancy and the application of ISA95 based Application integration within a wide variety of
Industries, from Food and Beverage to Plastics to Life Sciences and others.

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ISA95 Standards-
Practical Application in
Manufacturing

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Let's Talk ISA95 Business Value

ISA95 Technical Applications and Methods are globally
applied by innovative manufacturers to adapt and optimize
their manufacturing to 21 st Century "Pull" markets
> Dow, DuPont, Proctor & Gamble, Pfizer, BP, Nestle,
Anheuser-Busch, Coors, Ely Lilly, Busch, E&J Gallo, 3M,
Microsoft, SAP, IBM, Oracle

ISA95 / MESA Best Practice Technical Report centers on

ISA95 Business Case:
1. Lower life cycle cost of business-to-manufacturing (B2M)
interfaces
2. Constructing a Flexible Manufacturing Framework to
optimize B2M interoperability
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83
Why PM Technology??? 21st Century
Manufacturing is ALL ABOUT Flexibility
Business Drivers for Flexible Manufacturing
#1. Increased Globalization: global markets with
distributed sources of supply, production and
distribution facilities
#2. Increased customer diversity: culturally and
geographically
#3. Increased access to competitive data
#4. Increased level of expected value
#5. Increased outsourcing of production and
logistics operations
#6. Increased pace of NPIs
#7. Increased product quality @ lower cost

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Aligning Mfg. Capabilities to 21st Century

Challenges Mandates Change...
20th Century Manufacturing Flow s
Supplirs = ® Eiere

U i 5 - ll

UPPlI
Exchange
(..iC\
cha e xchanges/

; s L~~~~~~ogistics M
4 w t P~~~~roviders J
Copyright @2004 AMR Research:
All rights reserved.
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Business Evolves into Configurable
Demand-Driven Supply Chains
Need:
Production
Capability o

suppliert

Supplier ~AA\ cJbe

Alrihsrsre. DC- Ds. Channel
Supplier Cu*s.o.m\r

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21 st Century Profitability & Flexibility

Requires Production Performance

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ISA-95 Integrates Production
Capabilities into 21 st Century Model
Effective and Flexible Mfg. Operations
.....HA RD TO DO!'
* Various Forms of the MES I ERP solution:
0 Industry-specific production types 0
> Mixture of work order types across plant ma
> Speed and Volume of Throughput

* Standardization of work flow "best practices"

> Must Allow Change in Production Processes Without requiring
change in logistics system
> Provide a clear demarcation of MES / ERP responsibilities and
functions
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ISA-95: Functional Segregation

A Manufacturing Flexibility Framework
* ISA 95.00.01: Enterprise - Control System Integration
- Part 1: Models and Terminology
* .02: - Part 2: Object Attributes
* .03: - Part 3: Activity Models of MOM
* .04: - Part 4: Object Models & Attributes of MOM (Draft)
* .05: - Part 5: Business to Mfg Transactions (Vote)
* .06: - Part 6: Mfg. Operations Transactions (Proposed)

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ISA 95: Defines MOM and ERP+
Domains and Information Exchanges

2 - Monitoring, supervisory control and automated

control of the production process

87
ISA95: 19 MOM / ERP+ Data Flows
Product Work Flow Timing = Flexibility

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Identified Information Categories for

MOM / ERP+ Data Flows
rprseln
/Plant Producbon S:cheduling,\
orma
Operational Mlanagement, etc
roduatioiy,\P°Ut)
Producrdu,on f roductiob
Inforo>w _~~~~~~~~~~~I Performance
arVailable i/ro0 -ihb } -- ion
~ Cprodut
~~~~ us used

33:SutaQit} P~~~~~roron--Ptanning::
~~~~~~~t S I SA 2004.
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 ISA 95: 4x4 Object Model Defines
Business-to-Mfg (B2M) Data Exchanges
4 Resource Cateaories
- XIM
. --- - - - - 4 Information Cateaories
- --- -- -- - -0- - -- -- - - - - - - - --- - ---

Resources Product Capabilitv

People Equipment Materials Produ inition Time

Production Capability
Production
Structure View
Production
Iihedule

Segments
Productin Pe ormance

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Business to Mfg Markup Language

(B2MML): ISA95 Schemas

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 Exchanging Material Information
Picture below represents material information modeled in 95.01
This is only a subset of the complete material information
maintained by a company
Material Class Material Definition Lot Sublot
Acid HCI 50% HCL-50-1 00019 HCL-50-1 00019
Barrel 15

U NE
pH Density Color Purity QA Test QA Test Location
Results Specif ion

pH Density Color Purity

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Material Information Schema

* Defines material lots, material sublots,
material class, material definitions, and
QA Material Test Specifications ' Ges1cr#ptsn:
* A container for any type of material t sLoceton 4
information
., .

PL_. ,lisheedDate
The container for sharing material master
information (eg: SAP MM)
* Material Class Ment
H- hgaternalCsd,LnX
niate-rsaicteeL t
* Material Definition
A container for sharing material inventory
information (eg: SAP VV1I)
* Material Lot and Sublot GAMat-artMTcsoSpmec,Gat
An; t:

_ C

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MOM System Implementation Method
Simply Put...
Why
* Why is the information being exchanged
* Identify the business reason for the exchange
What
* What information is to be exchanged
* Defined using ISA95 terms, map to local terms
Who
* Who generates the information
* Who receives the information
When
* When is the information exchanged, event or time
How
* What is the specific mechanism to be used
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MOM Design Sequence

Business process modeling
- ---- (95 Part 3 Activity diagrams)
- Transactions identification
- ----=-
Data and Transaction design
Transactions, Triggers, Activities, Responsibility
Based on ISA95
Implementation framework. System architecture.
Technology, Information support, EAI usage,
Mes ges architecture: WBF B2MML, OAG, EbXML, Rose anet
Communication links & protocoles
Applications interfaces
Connectors design
Make It Alive
Triggering and execution of business processes,
activation of transactions
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ISA95 Part 3 FRS Functions
ISA95 Core Common FRS Elements
Production eManagement of Regulatory
- Detailed Planning Compliance
- Dispatching *Management of Information
- Execution *Management of Documents
- Data Collection
- Tracking
*Management of Changes
- Resource Management *Management of Security
- Definition Management
- Analysis
Maintenance, Inventory, Quality Test
- Above list

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Functional Requirements
Rpbfigation
* A BPR process produces documented MOM system functionality
- Defining for internal users, what and how system(s) is to provide
* Guides vendor and company to successful system implementation
* Describe:
- "As is" current condition
- Specific "to be" needs
- Physical system environment using 95 Activity Models

- Hardware and software preferences

- Performance Specification
- Legacy system requirements
- Support requirements
- Interface requirements

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ISA95.03 Manufacturing Operations
Functions for RFP and FRS
Product Production Production Production
definition capability schedule performance

l '-+ .~ ~ >~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ .
Prw, ~ t Prdcto

............., ...:

Equipment and Process Operatio t rational Equipment and Process

Specific Production Rules _,CQmma -- -rResponsedJ_Specific Data
Lev l
Producessontrol 8 From ISA-95 Copynght ISA 2004.
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Adorrieut ion

ISA 95 Benefits to
Lean & 6 Sigma Transformations
ISA95 Models & Terminology establish basis for:
* Lean Standard Work & 5S Transformation
* 6 Sigma Process & Analysis
Simplified through Lean Standard Work
(Common ISA95 terminology & data hierarchy)
ISA95 reinforces Lean practices, such as:
* Standard work flow practices for Quality, CID, ECO, RMA,
maintenance, planning, data entry methods, & route
* Cross-trained operators and maintenance mechanics
through Standard Work
* Single XML schema across all production application to
simplify and control interfaces and data exchanges
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Road Map

7ASo~ - _
Lean Manufacturing Transformation

< ~ ~ ~ ~ ~ ~ ~ ~~

~~~~~~~~~~~~~~. .
~

t~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

lA95 to accelerate
~

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~~

1te
S9
~ ~ ~~~~~~~~~~~~~~~~~~~--

. . .F. ....... ...

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. . ..r

........
-----

...g

GE Fanuc

GE Fanuc's
Production Transformation Process:
A Partnership Process, not an Event
* Onsite Operational Discovery (OOD): Site
* Production Performance Assessment (PPA):
Multi-Plant / Enterprise
Manufacturing Ops Profile
- Determine level of automation and production mgt.
Pain Profile
- Prioritize CTQs (Critical-to-Quality) from workforce input
- Cross-department agreement on project priorities
- Agreement on Pain Profiles for production environments
- Each department understands CTQs and priorities for migration
path
Solution Profile
- Determine production migration path
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ISA95:A Success Story for Standards

*ERP-to-MOM Integration cut from 9-12 months to 8-10 weeks

*MOM FRS development cut from 6-9 months to 6-9 weeks
*Industry acceptance
- End users use for RFP and Project Planning
- Vendors support their products:
- SAP, Oracle, Microsoft & IBM supported
*Many Alignment Working Groups:
- OAG, ISA88, SCOR, MIMOSA, OMAC, OPC, more

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ISA95 Business Values

* Consistent function models, schema and language
requirements for Interoperable, Flexible MOM / ERP
* Accurate flow of dynamic information from consistent
messaging between business and production systems
* Fast implementation of ERP+/MES integration projects
* LARGE reduction implementation and change costs for ERP
integration through use of single B2MML interface schema
* ISA88/95 methods structuring a Flexible Manufacturing
Framework over next 5 years

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Proficy Quantifies Production Capabilities
for 21 st Century Business Model
* Real-Time Decision Support Designed into Distributed
Supply Chain Systems
* Enabling Customers Achieve the Real-Time Enterprise

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Thank You

_ANUC
@E3:FAIUUC Automation
T +44 (0)1625 630 249
Paul Ashmore M +44 (0)7798 667 961
Commercial Proposal F +44 (0)1908 325 210
Engineer paul.ashmoreegefanuc.com
www.aefanuc.com
GE Fanuc Aulomation Americas, Inc

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