Transcript Practical Enterprise Modelling: ISA 88 and ISA 95 standards

Practical Enterprise Modelling:
ISA 88 and ISA 95 standards
IEC SB3 Sponsored Seminar
Workshop on Industrial Automation Objects
3-4 April 2001, Geneva, Switzerland
Jean Vieille, Consultant
ISA SP88 & SP95 committees member
[email protected]
Agenda
 ISA 88 and 95 in SCM and Production Scheduling
 ISA 95 : Enterprise-Production Communication
 ISA 88 : Modular Control
ISA 88 and 95 in SCM and Production
Scheduling
Market / Customer driven production
Classical Enterprise
Market /
Customer
demand
Production
Schedule
Product
Development
Resources
Engineering
Agile Enterprise
Market /
Customer
demand
Production
Schedule
Production
Schedule
Resources
Engineering
Product
Develoment
Enterprise
System 1
Manufacturing
Control System 1
Manufacturing
Control System 2
Enterprise
System 2
Company 2 with No manufacturing
Company 1 with
manufacturing
Manufacturing
Control System 3
Company 3 Contract manufacturer
S95.01 Scope
Business Logistics
Business Planning & Logistics
Systems
(ERP)
Level 4
Plant Production Scheduling,
Operational Management, etc
Interface addressed
in ISA 95.01 / 02
Level 3
Manufacturing
Operations & Control
Manufacturing
Operations Support
Levels
(MES)
2,1,0
Discrete
Continuous
Batch
dS95.03 Area
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Control
Systems
Control
Systems
Control
Systems
Source: ISA dS95.01 Enterprise/Control System Integration
S88
Manufacturing in The Supply Chain
 The Supply Chain
 The network of activities in a company that take place from
customer order to customer delivery
Delivery
Order Entry
Scheduling
Suppliers
Customer
Suppliers
Production
Suppliers
Distribution
Enterprise Resource Planning / Supply Chain Management
Materials
Product Production Manufacturing
Operations
Purchasing Development Planning
Distribution
& Logistics
Customer
Order
Management Service
SP95.01 Enterprise / Control System Integration
R
R
C
Recipe
Management
Production
Planning and
Scheduling
A
E
P
Order &
Inventory
Management
R
Production
Information
Management
A
E
Process
Management
Unit
Supervision
Process
Control
Process Management
C
C
P
Maintenance
Management
A
E
P
Warehouse &
Transportation
Management
Consumers
Suppliers
S95/S88 and The Supply Chain
S88 et S95
Enterprise A
« Product »
Enterprise B
« Product »
S88
S88
S95
Enterprise X
« Manufacturing »
S88
Quality
S88
Enterprise Y
« Manufacturing »
S88
S88
Process
Cell Y1
Process
Cell Y2
S95
Process
Cell X1
Process
Cell X2
Maintenance
S95.01 Production Schedule
Structure
Production Schedule
A Production Schedule is made
up of 1..n Production Requests
Production Request
A Production Request is made up
of 0..n Segment Requirements
Segment Requirement
A Segment Requirement may
contain 0..n of each
Production Personnel
Parameter Requirement
Material
Material
Equipment
Consumed
Produced
Requirement Requirement
Requirement
Consumable
Expected
Mixed Format Schedule Application
S95.01
Production
Schedule
Work
Dispatching
Setpoints
&
Flowpaths
Continuous
Premix
S88.02
Schedule
Entry
Setup
Instructions
Batch Production Discrete
Process
Packaging
S95 in Production System Lifecycles
Production
Schedule
Segment
Requirement
Product
Definition
Product
Development
Product
Segments
Process
Segments
Resources
Production
Capabilities
Resources
Engineering
S88 in Production System Lifecycles
Production
Schedule
S88 : Schedule
S88 : Resources
S88 : Recipe
Product
Development
S88 : Equipment
Procedural
Elements
Resources
Engineering
ISA 95 : Enterprise – Production
Communication
What is ISA95 ? Status
 SP95 committee started in October 1996
 ANSI/ISA95.00.01 available from ISA
 Submitted to IEC/ISO
 Joint Working Group (JWG 15) to be established
 ISA 95.00.02 in draft, out for vote
 Out for committee ballot and public comment
 ISA 95.00.03 in draft
 Still under development in the committee
 World Batch Forum
 Developing XML Schemas for the exchanged information
Some SP95 Committee Members / Supporters

Users
DuPont
Ben & Jerry's
Sterling
IBM
Nestle
Lyondell Chemical
Novo Nordisk
Tava Technologies
Aurora Biosciences
Pharmacia
Lubrizol
Bechtel
EastmanK
Genemtech
Procter&Gamble

 Eli Lilly
 Dow Corning
 Rohm & Haas
 Bayer
 Merck
 UOP
Vendors

 ABB
 SAP
 ABB
 Honeywell
 Marcam
 GSE SystemHP
General
AspenTech
Sequencia
Rockwell
FRSI
OSI
IBM GS
Siemens
InCode
Yokogawa Foxboro
InCode
Intellution
Microsoft
BaseTen
Wonderware
Propack Data
Oracle
Schneider Electric
ORSI
Fluor Daniels
PDXI
MIT
AMR
NAMUR
PWC LLC
Jacobs
Keops
 Purdue
 MESA
 KPMG
Why Did We Start SP95 ?
 Integration of business (logistics)
systems to manufacturing is
hard to do
 Different systems, cultures, terminology...
 Many benefits expected from standardization and documentation of
“best practices”
 Effective operation of manufacturing is hard
to do
 MES solutions are too related to processing methods and too
industry-specific
 Many benefits expected from standardization and documentation of
“best practices”
Business Defines the Need
 There must always be a business need for information
to be exchanged
 Requirements for exchanged information are always
driven by business needs & business processes
 Typical Business Drivers:





Available To Promise
Reduced Cycle Time
Supply Chain Optimization
Asset Efficiency
Agile Manufacturing
How Does S95* Help?
Alternate Logistics Strategies
 Separate the business
processes from the
manufacturing processes
 Allow changes in production
processes without requiring
unnecessary changes
scheduling and logistics
processes
Make
to
Order
Make
to
Stock
Engineer Configure
to
to
Order
Order
S95.01
 Provide a clear demarcation
of responsibilities and
functions
 Provide a clear description
of exchanged information
PDXI
NAMUR
S88.01
SME
Continuous
Manufacturing
Models
Batch
Manufacturing
Models
Discrete
Manufacturing
Models
Alternate Manufacturing Strategies
* S95 is used as a short form for ANSI/ISA95
Scope of S95.01
 The definition of the scope of the manufacturing control
domain
 A definition of the functions associated with the
interface between control functions and enterprise
functions
 A definition of the information which is shared between
control functions and enterprise functions
 Based on the Purdue Reference Model for CIM and
MESA model
SP95.01 Enterprise / Control
Functional Model (PRM)
Order
Processing
(1.0)
Product Cost
Accounting
(8.0)
Production
Scheduling
(2.0)
Product
Shipping Admin
(9.0)
Product
Inventory Control
(7.0)
Procurement
(5.0)
Maintenance Purchase
Order Requirements
Production
Control
(3.0)
Quality
Assurance
(6.0)
Material and
Energy Control
(4.0)
Marketing
& Sales
From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org
Research
Development
and Engineering
Elements of Models & Definitions
Domain
Definitions
(Responsibility)
Functions
in Domains
Functions
of Interest
Information
Definitions
Categories of
Information
Information
Flows of Interest
Identified Information Categories
 Data flow
information was
categorized
 Multiple Venn
diagrams used to
illustrate the
overlap of
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)
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc
Major Object Definitions
Resources
Capability, Product, Production
Product
People
Equipment
Materials
Segments
Time
Capabilities
Product
Definitions
Production
Schedule
Production
Performance
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
Material Definition Example
 Common material information
Material Class
Acid
pH
Density
Material Definition
HCl 50%
Color Purity
Lot
HCL-50-100019
QA Test
Results
pH
7.0
Sublot
HCL-50-100019
Barrel 15
Location
QA Test
Specification
Density Color Purity
1.32 Yellow .5%
Process Segments
 Business view of production
Assembly
Paint
Inspect
I-Beam
Laborer
3x
8 hour
Type =
Stainless
Steel
Inspector
2x
.25 Hour
Mixing
Cans
Rollers
Certified
Painter =
TRUE
Capability, Product, and Production
Information
What is available for use for production
Product
Time
Capabilities
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
Capability Models
Product
People
Equipment
Materials
Segments
Time
Capabilities
Per Product Definitions
Material
System
Scheduling
System
Bill Of Resources
e.g. 10 Speed Bicycle
Bill Of Materials
e.g. 10 Speed Bicycle
Product
Segments
Frame
Assembly
Final
Assembly
Paint
Color
Frame
Type
Seat
Height
Production Rules
e.g.
10 Speed Bicycle
Manufacturing
System
Manufacturing
Bill
Frame : 1
Wheels : 2
Chain : 1
Seat : 1
Handlebars :1
Brake Pads : 4
...
Production Schedule
People
Equipment
Materials
Segments
Product
Definitions
Production
Schedule
Production Performance
People
Equipment
Materials
Segments
Product
Definitions
Production
Schedule
Production
Performance
Four Models & Segment Resources
Production
Capability
Process
Specification
Product
Definition
Production
Scheduling
Production
Information
What resources
are available
What can be done
with the resources
What must be defined
to make a product
What is it to be
made & used
What was
made & used
Production
Schedule
Production
Performance
Production
Rule
Production
Request
Production
Response
Production
Capability
Process
Segment
Product
Segment
Segment
Requirement
Segment
Response
Resource
Capability
Resource
Segment
Capability
Resource
Specification
Resource
Requirement
Resource
Actual
Capability
Property
Segment
Property
Specification
Property
Requirement
Property
Actual
Property
ISA 95.00.02 : Relationship with Part 1
ISA95.01
Equipment
model
dISA95.02
Attribute
Name
ID
Equipment
Attributes
Description
A unique identification of a specific piece of R7726
equipment, within the scope of the information
Reactor 101
exchanged (Production Capability, Production
Lathe machine 33
Schedule, Production Performance, …)
The ID is used in other parts of the model when
the equipment must be identified, such as the
production capability for this person, or a
production response identifying the equipment.
Description
Examples
Additional information about the equipment.
ISA 95.00.03 : Level 3 Functions









MESA Definitions
Operations and Detailed Scheduling
Production Tracking
Dispatching Production
Resource Allocation and Control
Data Collection and Data Acquisition
Quality Management
Process Management
Performance Analysis
Interface to
 Document Control
 Labor Management
 Maintenance Management












d95.03 Definitions
Detailed Production Scheduling
Production Tracking
Production Dispatching
Resource Management
Historical Data Management
(QA) Product Analysis
Process Analysis
Production Analysis
Product Definition Management
Process Monitoring
Manual Operations
Automated Control
d95.03 Manufacturing Operations Functions
Product
Definitions
Production
Capability
Production
Schedule
Production
Performance
Detailed
Production
Scheduling
Production
Tracking
Resource
Management
(QA) Product
Analysis
Production
Dispatching
Historical
Data
Management
Product
Definition
Management
Production
Execution
Process
Monitoring
Manual
Operations
Process
Analysis
Production
Analysis
Automated
Control
ISA 88 : Modular control
What is ISA 88 ? - Status
 Standard ANSI/ISA 88 « Batch Control »
 Comité SP88 lancé en 1988
 Partie 1 – ISA 88.00.01
 Publiée et disponible à l’ISA et à l’ANSI
 IEC 61512-1 bilingue disponible auprès de l’IEC, l’UTE et l’AFNOR
 Partie 2 – ISA 88.00.02
 Publication imminente
 Version IEC (61512-2) bilingue pour 2001?
 Partie 3 – ISA 88.00.03
 Début des travaux
Automation Challenge
Ideal automation
Flexibility
S88
Manual
Operation
Darin Flemming
Lou Pillai
Capability
Traditional
Automation
Complexity
The Powerful Tyrex…
 Big brain
 Centralized design
 OK for steady / slow changing
environment
 Shortcomings
 Agility
 Availability
 Refer to first computerized systems
…vs Stupid Bird
 Limited intelligence
 Mostly decentralized design
 Local decision making at feather
level
 Cope well with unexpected
situations
 Inherently adaptative structure
From Goal to Labor
Forecasting,
Planning
And Scheduling
Process
Control
Definition
Equipment
Functional
Capabilities
The Goal:
I know
What/How
To do
Flying
chirping
Eating
Love.
Walking
Elementary
Equipment
Control
Scheduling hierarchy
Business system
ISA 95
MES systems
SCADA systems
Process
Control
Equipment
Control
« Intelligent »
Device
ISA 88
IEC 61512
OPC
IEC 61131
IEC 61499
IEC 61158
Fieldbus
Product Processing / Equipment Control
Equipment
allocation
Process
Control
Production
schedule
• How to make
the product…
•… using
available
services?
Equipment
Control
•How to provide
the expected
services…
• … taking care of
safety ?
ISA 88
R&D
ISA 88.00.02
(PFC)
IEC 60848
IEC 61131
IEC 61499
IEC 61508
IEC61158
ISA 88 Physical Model
Enterprise
May contain
Site
May contain
Area
May contain
Process Cell
Must contain
Unit
Equipment
May contain
Equipment Module
May contain
May contain
Control Module
May contain
Equipment Entities -An Object Approach
Physical
Equipment
Equipment
Entities
Equipment
Control
Instruments
Basic control
Coordination control
Procedural control
Example of physical modeling
Process Cell
Unit
EM
Unit
EM
EM
EM
CM
CM
CM
CM
CM
CM
Example of control modules
CM4
CM2
CM1
D1
PID
D4
D3
PID
PID
CM3
D5
D2
HIC
HIC
Why Control Modules
Treating as a control module simplifies the
interface to this group of objects
Commands
Status
Circulate
Circulating
Pump to
Process
Pumping
to Process
Stopped
FO
Stop
Shutdown
Shutdown
FC
Pump
Recipe/Equipment Control Separation
Equipment
Control
Control Recipe
Procedure
Recipe
Procedure
[Must Always Exist]
Procedure
is an
ordered set of
Unit
Procedure
is an
ordered set of
Operation
is an
ordered set of
Phase
Equipment
Phase
Recipe/Equipment Control Separation
- Typical
Equipment
Control
Control Recipe
Procedure
Recipe
Procedure
is an
ordered set of
Recipe Unit
Procedure
is an
ordered set of
Recipe
Operation
is an
ordered set of
Recipe
Phase
References
Equipment
Phase
Recipe/Equipment Control Separation Alternate 3
Equipment
Control
Control Recipe
Procedure
Recipe
Procedure
References
Equipment
Procedure
is an
ordered set of
Equip. Unit
Procedure
is an
ordered set of
Equipment
Operation
is an
ordered set of
Equipment
Phase
Phase Interface Logic
 State machine enforcement between recipe phase and
equipment phase
 A set of services that support commands to the
equipment phase
 A set of services that support requests from the
equipment phase to the recipe phase
Recipe
Phase
Phase
Interface
Logic
Equipment
Phase
Phase Interface Logic
Requests
Parameters
Commands
State
Machine
States
Phase Object
Parameters
Data
Start
Run
Hold
Held
Pause
Aborting
Paused
Pausing
Stop
Stopped
Abort
Aborted
Reset
Idle
Holding
Resume
Running
Stopping
Restart
Control
Action
Status
Data
Collection
Requirements
Completed
Restarting
Control
Steps
Example Procedural Element States
Restart
Complete
Held
Restarting
Holding
Reset
Hold
Idle
(Initial
State)
Start
Pause
Running
Resume
Abort Stop
Aborting
Aborted
Pausing
Stopping
Paused
Final States
Stopped
Reset
Reset
Quiescent States
Transient States
Exception Handling In Control Actions
The safety interlock logic takes precedence over
phase logic or process interlock logic. Typically this
logic, when required, is implemented in an
independent safety interlock system.
Safety
Interlock
Control Module
Process
Interlock
Control Module
Exception Logic
The process interlock logic takes precedence
over phase logic and manual override logic.
Typically, this logic is implemented in the
DPCS.
Phase
Logic
Control step (command)
Control
Action
Control Module/Control
Action State/Mode
Equipment Module
Control Module
Inhibit manual override
(Interlock from phase logic),
Also sent to console to inhibit
choice of manual mode
Console
Control
Control Module/Control
Action State/Mode
Field I/O
Exception Logic
Inputs to Control Action Logic:
- Set manual mode
- Command from operator's
console
ISA 88.00.02 : Procedural Function Chart
 Unit procedure interactions
 Relative timing
Tank
A, B or C
Preparation
S1
Reactor
1 or 2
operator input
= OK to start
Initialize
Reaction
 Synchronization points
Charge
S1
Sample
S1
Initialize
Sample
OK
Transfer to
Reactor
T1
T1
 Height of unit procedure symbol
 Vertical placement of symbols
 Master recipes do not contain
absolute timing
T1
T1
Receive
from Prep.
React
Transfer to
Storage
 Arrowheads indicate material
transfer
 Multiple levels of procedures
 Encapsulation (contents) of unit
procedure revealed
 Provides more detail
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