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NORMA ISA 95Enterprise-Control System Integration StandardEnterprise-Control System Integration Standard
B2MMLB2MMLBusiness To Manufacturing Markup LanguageBusiness To Manufacturing Markup Language
2
Companies Participating in SP95Companies Participating in SP95
ABBArla FoodsAspenTechDupontEli LillyEmerson Process ManagementFluor General ElectricInvensys-WonderwareLighthammer
Lund University, SwedenLyondell – EquistarMicrosoftNestleNovo NordiskProctor & GamblePurdue UniversityRockwell AutomationSAPSiemensYokogawa
3
Why was ISA-95 Created?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 integrationIncrease in business needs to integrate manufacturing sites with business systemsBusiness drivers: Supply chain optimization Asset efficiency Agile manufacturing Available to Promise & Available to Profit
4
What ISA-95 OffersWhat ISA-95 Offers
Framework for integration projects
Separation of business processes from manufacturing processes
Focus on functions, not systems, organizations or individuals
5
SITE
AREA AREA AREA
CONTINUOUSPRODUCTION
UNIT
DISCRETEPRODUCTION
LINE
ENTERPRISE
ISA-95 ScopeISA-95 Scope
95.0395.03
95.01 & 295.01 & 2
BATCHPROCESS
CELL
6
Information of InterestInformation of Interest
FunctionsOutside the
Control Domain(e.g. Production Scheduling)
(e.g. Production Schedule and Production Results)
Information Flows of interest
FunctionsWithin the
Control Domain(e.g. Equipment Monitoring)
Enterprise/Control System Boundary
Functions detailed
Functions not detailed
Data flows detailed
Data flows not detailed
7
Categories of InformationCategories of Information
Pro
du
ctio
nR
esp
on
se P
rod
uctio
n
Sch
edu
le
Business Planning &Logistics Information
Pro
du
cti
on
De
fin
itio
n
Manufacturing Operations &Control Information
Pro
du
cti
on
Ca
pab
ility
Resource Availability
Manufacturing Instructions, Recipes, BOM,
What to make, when to make it , what to use
What was made and used
8
Major Object ModelsMajor Object Models
Three categories of resources
Personnel Equipment Material (and Energy)
Combined resources (logical view) Process Segments
Four Models / Production-Process-Product Production Schedule Production Performance Capability Definition (by time & by segment) Product Definition
9
Design PatternsDesign 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
Necesidades de Importantes empresas del mundo
+Experiencia de los Principales proveedores
de soluciones tecnológicas
=Norma ISA 95
Definición de ModelosDefinición de Modelos
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
13
Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc
Manufacturing Operations & Control
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
BatchControl
DiscreteControl
ContinuousControl
Level 4
Level 3
Levels2,1,0
Scheduling and control hierarchy
Interface addressedParts 1 & 2
Area addressedParts 3 & 4
14
Level 3 activitiestypically deal with
these objects
ENTERPRISE
SITE
AREA
PRODUCTIONLINE
WORKCELL
PRODUCTIONUNIT
PROCESSCELL
UNIT
Level 4 activitiestypically deal with
these objects
Lower level equipment usedin repetitive or
discrete production
Lower level equipment used
in batchproduction
Lower level equipment used
in continuousproduction
STORAGEZONE
STORAGEMODULE
Lower level equipment used
for storage
Equipment hierarchy model
Enhanced in Part 3
Functional data flow model
6 Functional data flow model
OAGi General Meeting ISA-95 - B2MML Briefing 16May 2, 2006
Reference ModelReference Model
Procurement(5.0)
ProductionScheduling
(2.0)
Material andEnergy Control
(4.0)
ProductInventory Control
(7.0)
Product CostAccounting
(8.0)
QualityAssurance
(6.0)
ResearchDevelopment
and Engineering
ProductShipping Admin
(9.0)
OrderProcessing
(1.0)
Marketing& Sales
ProductionControl
(3.0)
MaintenanceManagement
(10.0)
Pack Out Schedule
Finished Goods Inventory
Finished Goods W
aiverProcess Data
Short Term Materialand Energy Requirements
Material and EnergyInventory
Production Capability
Production From Plan
Schedule
Incoming material and
energy receipt
Pro
duct
ion
Cos
t
Obj
ectiv
es
Pro
duct
ion
Per
form
ance
and
cos
t
Con
firm
to
ship
Rel
eas
e to
shi
p
QA
Res
ults
Pro
duct
and
Pro
cess
Req
uire
men
ts
Standards and
Customer
Requirements
Standards and Customer
Requirements
In Process WaiverRequest
Process Data
QA Results
Product and P
rocess Know
How
Product and P
rocess Technical Feedback
Mai
nten
anc
e S
tand
ard
san
d M
etho
ds
Ma in te na
n ce Te c hni c alF
eedbac k
Maintenance
Purchase Order
Requirements
Material and
Energy O
rder
Requirem
ents
Incoming
Order
Confirm
ation
Long
Ter
m
Mat
eria
l and
ener
gyre
quire
men
ts
Production O
rders
Availability
Product and P
rocess Information R
equest
Mai
nten
anc
e R
equ
est s
Ma in ten a
nce Res p
ons es
Enterprise/Control
Boundary
Functional data flow model
7 Object Model
7.1 Categories of information 7.3 Production capability information
18
Identified Information CategoriesIdentified Information Categories
Manufacturing operations &control information
Production operations, maintenanceoperations, quality operations, etc
Business planning &logistics information
Plant production scheduling,operational management, etc
Productdefinition
information(What must be
defined to makea product)
Productioncapability
information(What resources
are available)
Productionschedule
information(What to
make and use)
Productionresponse
information(What was
made and used)
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
28
Personnel ModelPersonnel Model
PersonProperty
PersonnelClass
Hasvalues for
0..n
0..n
0..n
0..n
0..n
0..n
0..n
1..n
HasProperties
of
Is testedby a
Maps to
Defined by
Records theexecution ofDefines a
procedure forobtaining a
Person
PersonnelClass Property
QualificationTest
Specification
QualificationTest
Result
29
Persons and Personnel ClassesPersons and Personnel Classes
Supervisor LaborerProfessionalEngineer
Operator PumpMechanic
Draftsman
Joe Smith - ID#12345Sally Jones- ID#12344
QualificationTest
QualificationTest Results
30
Equipment modelEquipment model
MaintenanceWork Order
May be generated for0..n
1..1
1..1
1..1
EquipmentProperty
EquipmentCapability TestSpecification
Hasvalues for
0..n
0..n
0..n
0..n
0..n
Equipment0..n
0..n1..n
HasProperties
of
Is testedby a
Maps to
Defined by
Records theexecution of
0..n 0..n May result in
0..1
May be made up of
Is against
Is madeagainst
0..n
0..n
Defines aprocedure forobtaining a
EquipmentCapability Test
Result
MaintenanceResponse
EquipmentClass Property
MaintenanceRequest
EquipmentClass
31
Equipment and ClassesEquipment and Classes
Mixing ReactorHeating Reactor
HR101 HR102 HMR101 MR101 MR102
MaintenanceRequest
MaintenanceWorkOrder
CapabilityTest
CapabilityTest Results
MaxTemp =300 F
Capacity=5000 Gal
Shearing=TRUE
Capacity=3000 Gal
32
Material modelMaterial model
MaterialSublot
May be made upof sublots
0..n
0..n
0..n
MaterialDefinitionProperty
QA TestSpecification
MaterialDefinition
Hasvalues for
0..n
0..n
0..n
0..n
0..n
Material Lot
QA TestResult
1..1
0..n1..n
HasProperties
of
Is testedby a
Maps to
Defined by
Records theexecution of
Made up of
MaterialClass
Property
MaterialClass
0..n
HasProperties
of
0..n
Definesa grouping
Is associatedwith a
Maymap to
Defines aprocedure forobtaining a
Material LotProperty
33
Material Definition ExampleMaterial Definition Example
LotHCL-50-100019
pH1.0
Density1.05
ColorStraw
Purity99.5%
Material
Definitio
n
Material DefinitionHCl 50%
Color PuritypH
Material ClassHCl Acid
Material
Class
Density
SublotHCL-50-100019
Barrel 15
LocationQA TestSpecification
QA TestResults
34
Process Segment ModelProcess Segment Model
People
Materials
Equipment
Segments
Personnel resources managed for production
Equipment resources managed for production
Material resources managed for production
Collections of resources, used together for production, at the granularity needed for business level scheduling and costing
Process Segment ModelProcess Segment Model
36
Process SegmentsProcess Segments
Business view of production
Inventory trackedfor Active Ingredient
Inventory trackedfor Pills
Inventory trackedfor Pill Packs
Pharmaceutical Manufacturing(3 Segments)
MakeActive
Ingredient
MakePills
PackageDosesRaw
MaterialsFinishedProducts
Know throughput,resources and time to
make Active Ingredient
Know throughput,resources and time to
make Pills
Know throughput,resources and time to
make Pill Packs
7.4 Product definition information
7.5 Production information
7.5.1 Production Schedule ModelProduction Schedule Model
7.5.2 Production Performance Model7.5.2 Production Performance Model
39
Production, Capability, ProductProduction, Capability, Product
ProductionSchedule
ProductionPerformance
What to make and resources to use
What was made and resources actually used
ProductDefinitions
What is available for use for production
What is needed to make a product
Product
Time
Capability/Capacity
40
Production ScheduleProduction Schedule
People
Materials
Equipment
Segments
ProductDefinitions
ProductionSchedule
41
7.5 Production Schedule Model7.5 Production Schedule Model
PersonnelRequirement
EquipmentRequirement
Material ProducedRequirement
PersonnelModel
EquipmentModel
MaterialModel
Corresponds toelement in
Corresponds toelement in
Corresponds toelement in
May contain
0..n 0..n0..n0..n
1..n
PersonnelRequirement
Property
EquipmentRequirement
Property
Material ProducedRequirement
Property
1..n 1..n 1..n
ProductionSchedule
ProcessParameter
Material ConsumedRequirement
Corresponds toelement in
0..n
Material ConsumedRequirement
Property
1..n
ConsumableExpected
0..n
ConsumableExpectedProperty
1..n
SegmentRequirement
1..n
Is made up of
Is made up of
Is associatedto either
ProductProduction
Rule
RequestedSegmentResponse
Correspondsto a
Correspondsto a
ProductionParameter
ProductionRequest
0..n
ProcessSegment
ProductParameter
42
Production Performance Production Performance
People
Materials
Equipment
Segments
ProductDefinitions
ProductionSchedule
ProductionPerformance
43
7.5 Production Performance Model7.5 Production Performance Model
PersonnelActual
EquipmentActual
Material ProducedActual
ProductionData
PersonnelModel
EquipmentModel
Material
Model
Corresponds toelement in
Corresponds toelement in
Corresponds toelement in
May contain
0..n 0..n0..n0..n
1..n
PersonnelActual
Property
EquipmentActual
Property
Material ProducedActual
Property
1..n 1..n 1..n
ProductionPerformance
ProductionResponse
Material ConsumedActual
Corresponds toelement in
0..n
Material ConsumedActual
Property
1..n
ConsumableActual
0..n
ConsumableActual
Property
1..n
SegmentResponse
1..nIs made up of
Is made up of
ProcessSegment
Correspondsto a
Resumen
45
Production Schedule ApplicationProduction Schedule Application
ISA-95ProductionSchedule
Setpoints&
Flowpaths
Dispatching
SetupInstructions
BatchSchedule
ContinuousPremix
Batch ProductionProcess
DiscretePackaging
Multiple levels of planning & scheduling
Quarterly
Monthly
Weekly
Dispatch to Production
Production schedules often must be split to multiple control systems & multiple process types
OAGi General Meeting ISA-95 - B2MML Briefing 46May 2, 2006
ISA-95 Functional HierarchyISA-95 Functional Hierarchy
Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc
ManufacturingOperations & Control
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
ContinuousControl
Level 4
Level 3
Levels2,1,0
Parts 1, 2 & 5focus on thisInterface
DiscreteControl
BatchControl
Parts 3 & 4 Focus onManufacturingOperations
OAGi General Meeting ISA-95 - B2MML Briefing 47May 2, 2006
Datacollection
Executionmanagement
Resourcemanagement
Dispatching
Tracking
Operationsresponse
Detailedscheduling
Operationsrequest
Definitionmanagement
Analysis
Operationscapability
Operationsdefinitions
ISA-95 Part 3 Generic ModelISA-95 Part 3 Generic Model
48
4 Sets of Level 3 Activities4 Sets of Level 3 Activities
ResourseManagement
QualityManagement
InventoryManagement
ProductionManagemen
t
datacollection
executionmanagement
resourcemanagement
dispatching
tracking
Detailedscheduling
definitionmanagement
performanceanalysis
datacollection
executionmanagement
resourcemanagement
dispatching
tracking
Detailedscheduling
definitionmanagement
performanceanalysis
datacollection
executionmanagement
resourcemanagement
dispatching
tracking
Detailedscheduling
definitionmanagement
performanceanalysis
datacollection
executionmanagement
resourcemanagement
dispatching
tracking
Detailedscheduling
definitionmanagement
performanceanalysis