Manufacturing Operations Management
Dennis Brandl BR&L Consulting Peter Owen Eli Lilly & Co
Dennis Brandl
Objectives
Review the ISA 95 standards and how they are being used in companies like Eli Lilly & Company for shop floor to top floor integration
The standards provide a formal model for exchanged data between business systems and manufacturing systems The models provide a definition of Manufacturing Operations Management, the activities on the shop floor that take production schedules and perform the actual work required to manufacture products and provide visibility of production
The Manufacturing Operations Management models are currently being used in the development of multiple new manufacturing facilities
Dennis Brandl & Peter Owen
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
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Collaborative Manufacturing Help
Fortunately there are multiple standards in place to help integrating business systems with manufacturing systems.
The ISA 95 Enterprise/Control System Integration standards, also an IEC/ISO standard XML Schemas standards for collaborative manufacturing from the World Batch Forum
Will show how they are being applied to the development of manufacturing systems roadmap
Dennis Brandl & Peter Owen
Different Points of View
Business Systems
Time Horizons
Long-term view
Manufacturing Systems
Time Horizons
Real-time view
Model detail
Linear route structures
Model detail
Complex routes with rework paths
Control emphasis
Product cost and overall profitability
Control emphasis
Physical movement & accountability
Modeling criteria:
Accounting reference points Has inventory value changed significantly? If not, dont model separately
Modeling criteria:
material movement reference points Does product stop moving? If not, dont model separately
View from the boardroom
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View from the workcenter
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Philosophical Orientation
Enterprise Management systems:
How much is my stuff worth? How much stuff do I have/need?
Manufacturing Operations Systems:
How do I make my stuff? Where is my stuff?
Dennis Brandl & Peter Owen
ISA 95 Provides Direction
The ANSI/ISA 95.00.01 Enterprise - Control System Integration - Part 1: Models and Terminology
Also Draft International Standard ISO/IEC 62264-1
ANSI/ISA 95.00.02 Enterprise - Control System Integration - Part 2: Object Attributes Draft ISA 95.00.03 Enterprise - Control System Integration - Part 3: Activity Models of Manufacturing Operations Management
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ISA 95 Control Hierarchy Levels
Level 4
Plant Production Scheduling, Shipping, Receiving, Inventory, etc
Business Logistics
Level 3
Manufacturing Operations Management
Dispatching, Detailed Production Scheduling, Production Tracking, ...
Interface addressed in the ISA 95.01 and ISA 95.02 standard Area addressed in the ISA 95.03 standard
Level 2 Level 1 Level 0
Dennis Brandl & Peter Owen
Batch Production Control
Continuous Production Control
Discrete Production Control
The production processes
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ISA 95 Control Hierarchy Levels
Business Logistics Logistics Business Level 4 Management Interface addressed (ERP) in the ISA 95.01 and ISA 95.02 standard Manufacturing Area addressed Manufacturing Operations Management Level 3 in the ISA 95.03 standard Operations Management (MES, LIMS, AM, )
Plant Production Scheduling, Shipping, Receiving, Inventory, etc Dispatching, Detailed Production Scheduling, Production Tracking, ...
Level 2 Level 1 Level 0
Dennis Brandl & Peter Owen
Batch Production Control
Continuous Production Control
Discrete Production Control
The production processes
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ISA 95 Part 1 and Part 2 Exchanged Information
Information that crosses the boundary between business systems and manufacturing systems
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Exchanged Information Categories
Enterprise Information
Plant Production Scheduling, Operational Management, etc
Production Product Production Production Capability Definition Schedule Performance InformationInformation (What to (What was
(What is available for use) (How to make a product) make and use) made and used)
Area Supervision, Production Planning, Reliability, Assurance, etc
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Manufacturing Control Information
4x4 Object Models
Four categories of resources
Personnel Equipment Material (and Energy) Process Segments Capability & Capacity Definition Product Definition Production Schedule Production Performance
Four Process, Product, & Production Models
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Four Resource Object Models
Personnel resources managed for production
People
Equipment resources managed for production
Equipment
Material resources managed for production
Materials
Business view of production processes
Process Segments
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Capability, Product, Schedule, and Performance Information
What is available for use for production
Product
Time
Capability/Capacity
What is needed to make a product
Product Definitions
What to make and resources to use
Production Schedule
What was made and resources actually used
Production Performance
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Production Schedule
Production Schedule Production Request Segment Request Expected Produced Material Expected Consumed Material Expected Personnel Expected Equipment Production Parameters What to make - Priority and/or dates - What materials to use - What equipment to use - What personnel to use - Production parameters (e.g. Color, Options,)
People
Equipment
Materials
Production Schedule
Segments
Dennis Brandl & Peter Owen
Per location (Site, Area, ) Per week, day, shift, order,
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Production Performance
Production Performance Production Response Segment Response Produced Material Actual Consumed Material Actual Personnel Actual Equipment Actual Production Data What was made - What material was actually produced - What materials were actually consumed - Equipment used - Personnel used - Production data (e.g. Purity, density,)
People
Equipment
Materials
Segments
Dennis Brandl & Peter Owen
Production Performance
Per location (Site, Area, ) Per shift, hour, end of batch,
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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 V2.0
One schema for each object model Formal way to exchange information
www.wbf.org
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An XML Example Material Lot
<Material <MaterialLot> <ID> W89 </ID> <Description> A lot of material </Description> <MaterialDefinitionID> WXE908 </MaterialDefinitionID> <Location> Tank 1 </Location> <Quantity UnitOfMeasure = "KL" > 4500 </Quantity> <MaterialLotProperty> <ID> dateTimeProduction </ID> <Value> 2001-01-06T00:14:23+11:30 </Value> </MaterialLotProperty> <MaterialLotProperty> <ID> Quality Status </ID> <Value> Good </Value> </MaterialLotProperty> </MaterialLot> </Material>
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ISA95 Part 3 Activity Models of Manufacturing Operations
In Development Expected Release 2004
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Order Processing (1.0)
Product Cost Accounting (8.0)
Product Shipping Admin (9.0)
Production Scheduling (2.0)
PRODUCTION OPERATIONS
Production Control (3.0)
INVENTORY OPERATIONS
Material and Energy Control (4.0)
INVENTORY OPERATIONS
Product Inventory Control (7.0)
QUALITY ASSURANCE OPERATIONS MAINTENANCE OPERATIONS
Maintenance Management (10.0) Quality Assurance (6.0) Marketing & Sales Research Development and Engineering
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Procurement (5.0)
Dennis Brandl & Peter Owen
Product definition
ISA 95.03 Manufacturing Operations Functions
Production capability Production schedule Production performance Detailed production scheduling Production resource management Production dispatching Product definition management Production execution
Equipment and Process Specific Production Rules Operational Commands Operational Responses Equipment and Process Specific Data
Production tracking Analysis Production data collection
Level 2 Process Control
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Other Enterprise Activities in Manufacturing Operations
Production, Maintenance, Inventory, Quality Management of information, compliance, security, documentation, and configurations
Level 4 Level 3
Inventory Operations Management of Information Quality Operations Management of Configuration
Maintenance Operations Production Operations
Management of Security Management of Compliance
Activity detailed
Management of Documentation
Level 2
Activity not detailed Activity outside scope
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Implementations
Nestle
Project to use the XML schemas for schedule exchange
Arla Foods
Project to use XML for standard interfaces to multiple ERP systems and MES systems
Empersas Polar
Project to use XML schemas for schedule exchange
Eli Lilly
Projects to use ISA 95 models for manufacturing operations management architecture
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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
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ISA 95 Control Hierarchy Levels
Level 4
Plant Production Scheduling, Shipping, Receiving, Inventory, etc
Business Logistics
ISA IEC/ISO Interface Standards
Level 3
Manufacturing Operations Management
Dispatching, Detailed Production Scheduling, Production Tracking, ...
ISA Functional Model
IEC, OPC, & OMAC Interface Standards
Level 2 Level 1 Level 0
Dennis Brandl & Peter Owen
Batch Production Control
Continuous Production Control
Discrete Production Control
The production processes
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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 1-2) 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
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Conceptual Topology IT View
Level 4
Business Process Information Network
ERP, APO, Logistics Systems
Level 3
Operations Information Networks
MES, LIMS, WMS, CMM Systems
Level 2
Automation Networks
HMI, SCADA, Batch Systems
PLC, DCS, Packaged Systems
Discrete & Process Device Communication Networks
Level 1
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I/O, Devices, Sensors
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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 plant safety The function is critical to product quality The function is critical to plant reliability The function is critical to maintaining regulatory compliance.
Includes such factors as safety, cGMP, and environmental compliance Maintaining FDA, EPA, USDA, OSHA, TV, EU, EMEA, and other agency compliance
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Functional Areas From ISA 95 & 88
Business Process Information Network
Detailed Scheduling Resource Management Production Tracking Networking Networking Networking Networking
Level 3
Product Definition Management
Production Dispatching Production Analysis
Production Execution Configuration Management
Operations Information Networks
Level 2
Alarm Management Operator Visibility
Operator Control
Supervisory Control Recipe Control
Equipment Information Collection
Automation Networks
On/Off Control Continuous Control Phase Control
Programmed Control
Interlock & Safety Control
Discrete & Process Device Communication Networks
Level 1
Sense Events Manipulate Equipment
Sense Process Manipulate Process
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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
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Logical Architecture IT View
Centralized Servers Desktop Reports and Analysis
Reporting HMI Engineering Tools
Investigations, Trends, Diagnostics, analysis,
Level 3
Business Information Network Fault tolerant Permanent Database Operations Control
Site Data Storage ERP Connection Area Data Storage MES
Operations Information Network
Operator Control Production Areas Batch Execution Real-time Data and Buffering Real-time Control and Data Collection
Supervisory HMI Recipe Execution Data Acquisition
Automation Network
Level 2
Controllers Packaged Equipment Sensors/Actuators Process/Equipment
Device Connection & /Networks
Level 1
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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
Physical architecture depends on the solution set used:
Vendor capabilities Networks Security and network management
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Dennis Brandl & Peter Owen
DataBase Servers
Ethernet
One Instance Per Site Historian Reporter
Domain Ctrl DNS VLAN Switch
Level 3
2 way Firewall
Site Information Network
Eng Tools Diag Tools
High Alarm Low Alarm Comm. Err.
ERP Connection
Network Management Router
Ethernet VLAN Switch
Configuration Server
MES Server
Domain Ctrl DNS
Area Operations Information Networks
Network Management Router
Non operations tools and views into data
Ethernet
HMI Server Historian Collection Gateway OPC Ethernet
Network Management Router
HMI Viewer
High Alarm Low Alarm Comm. Err.
Batch Execution
WMS Execution
Level 2
One Instance Per Process Cell
Automation Networks
PLC
DCS
Embedded PC
Packaged Equip
Device Networks
Level 1
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Dennis Brandl & Peter Owen
XML
Physical Architecture IT View
Conclusions
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
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Status
ISA95.00.01 & ISA.95.00.02 available IEC/ISO 62264-1 available from IEC & ISO ISA 95.00.03 in draft
Still under development in the committee
World Batch Forum
Developed XML Schemas for the exchanged information
Vendors
Many currently using ISA-95 models in development and current products
Users
Specifying ISA-95 in their RFPs
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