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Specialty
Chemicals & Life
Science
Presented by: Michael Purcell
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© Copyr i gh t 2015 O SIs o f t , LLC .
Challenges
• Management• Cost• Sustainability
Energy/Utilities
• Facilities/Manufacturing Shop Floor
• Raw Material Usage
• Metering
• Managing Costs• Understanding Usage Peaks/Patterns
• Optimize usage periods/sources/pricing
• Understand Usage Demands per recipe/product
© Copyr i gh t 2015 O SIs o f t , LLC .
Challenges
• cGMP• Batch/Lot
Analysis• Environmental
Compliance
• Out of the box functionality
• 450+ off the shelf Interfaces
• Supports Regulatory Compliance• Audit Trail
• 21 CFR part 11
• ISA-88 /95
• Environmental Reporting for Sustainability
© Copyr i gh t 2015 O SIs o f t , LLC .
Challenges
• Data Normalization
• Process Stability
• Visibility
Standardization
• Normalize Data
• Standard Equipment Models
• Naming Conventions
• Consistent Visualization & Reporting
• Consistent view from product/process development through manufacturing
© Copyr i gh t 2015 O SIs o f t , LLC .
Challenges
• Batch/Lot Reporting
• Operational Excellence
• Process Optimization
• Real time decisions
Data Access
• Situational awareness enables real time decision making
• Secure/Enterprise-wide access to real time data
• Multiple Options for End Users
• Mobile Devices
• Thick & Thin Client Tools
• Strong Partner Community
© Copyr i gh t 2015 O SIs o f t , LLC .
Challenges
• MES• BES• Disparate
Automation• S95
Data Integration
• Enterprise Manufacturing Intelligence (EMI) Infrastructure
• MES Interfacing Strategies
• PAS-X, Simatic IP, Syncade, and more
coming
• 450+ off the shelf Interfaces
• DCS, BES, SCADA, PLC, MES, LIMS, etc.
• Smart/Self Configuring Connectors
© Copyr i gh t 2015 O SIs o f t , LLC .
Challenges
• MES• BES• Disparate
Automation• S95
Data Integration
• Enterprise Manufacturing Intelligence (EMI) Infrastructure
• MES Interfacing Strategies
• PAS-X, Simatic IP, Syncade, and more
coming
• 450+ off the shelf Interfaces
• DCS, BES, SCADA, PLC, MES, LIMS, etc.
• Smart/Self Configuring Connectors
© Copyr i gh t 2015 O SIs o f t , LLC .
“Enterprise manufacturing intelligence (EMI) software is a suite of software
applications that integrates a company's manufacturing data from multiple
sources to aid in reporting, analysis, visual summaries and passing
data between enterprise-level and plant-floor systems. The combined
data can be given a new structure to make locating information easier. ”http://searchmanufacturingerp.techtarget.com/definition/manufacturing-intelligence-software
Copyright 2011 MESA North American Conference
Enterprise Manufacturing Intelligence
© Copyr i gh t 2015 O SIs o f t , LLC .
• Aggregation– data from many sources, including databases.
• Contextualization– flexible data model, including ISA-S95 standard and others
– link data to specific batches, equipment, and events
• Analysis– analyze data across production sites
– real-time ad hoc analysis and reporting
• Visualization– configurable visual summaries, including dashboards
– real-time alerts and actionable insights
• Data, Event and Information Propagation– line-of-business integration
– plant-floor to enterprise systems such as SAP, or vice versa
EMI - Core Functions
© Copyr i gh t 2015 O SIs o f t , LLC .
ISA S95
ISA S95 Architecture
Level 4: ERP
Level 3: MES
Level 2
Level 1
Manufacturing Operations
Management
Batch
Control
Continuous
Control
Discrete
Control
Business Planning & Logistics
SC
AD
A /
PL
C / D
CS
Level 0: Equipment
L4 – Establishing the basic plant schedule – production, material
use, delivery, and shipping. Determining the inventory levels.
Time Frame: Months, weeks, days, shifts
L3 – Work flow / recipe control, stepping the process through
states to produce the desired end products. Maintaining records
and optimizing the production process.
Time Frame: Shifts, hours, minutes, seconds
L2 – Monitoring, supervisory control and automated control of the
production processes
L1 – Sensing the production process, manipulating the
production process
© C o py r i ght 2015 OS Iso f t , LLC .
© Copyr i gh t 2015 O SIs o f t , LLC .
ISA S95
Real Time Data Infrastructure: A Key Enabler
Level 3: MES
Level 4: ERP
Real-Time Data InfrastructureCommon Data Presentation Layer
Event Frames& Batch
Electronic Work Instructions
Process data, Building automation data,
Alarm & Events
PI System
PI
Server
Time-Series
PI AF
Assets
PI EF
Downtime
Excursions
Batch
Events
ReferencedData
Data Access
Level 2
Level 1
Level 0: Equipment
Batch
Control
Continuous
Control
Discrete
Control
SC
AD
A /
PL
C / D
CS
PI Data Access
© Copyr i gh t 2015 O SIs o f t , LLC .
ISA S95
Level 3: MES
Level 4: ERP
Real-Time Data InfrastructureCommon Data Presentation Layer
Event Frames& Batch
Electronic Work Instructions
Process data, Building automation data,
Alarm & Events
ReferencedData
Data Access
PI System
PI
ServerTime-Series
PI AF
Assets
PI EF
Events
PI Data Access
The PI System Integration with Analytics
Analysis/Reporting Services
MII
© Copyr i gh t 2015 O SIs o f t , LLC .
Productiondata
collection
Productionexecution
management
Productionresource
management
Productiondispatching
Productiontracking
Productionperformance
Detailedproductionscheduling
Productionschedule
Productdefinition
management
Production level 1-2 functions
ProductionPerformance
analysis
Productioncapability
Productdefinition
Equipment and process
specific production rules
Equipment and
processspecific data
Operational
responses
Operational
commands
Functions that the PI System
should participate in
Functions outside of the
PI System
© Copyr i gh t 2015 O SIs o f t , LLC .
Interfacing Strategy – Current/Future
Process Control System(s)
MES
Production Data Collection
(Continuous, Batch,
Equipment)
Common Plant
Floor
Presentation
Layer to
support
Execution
Electronic Work
Instruction (EWI),
MES
Synchronization
CURRENTRecipe Param Downloads /
Operational Commands &
Synchronization
PI Server
Standard PI
Interfaces (450+),
BES Interfaces
PI Server, PI AF,
PI Data Access, HA
MES
Interfaces
OptionOperational Commands &
SynchronizationRecipe Param Downloads
FUTURE Operational Commands &
Synchronization & Recipe Param Downloads
ERPEMI Integration
EMI Integration
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Contact Information
Director of Industry
OSIsoft, LLC
16
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