Transcript How to use ISA95 part 3 for MES functional URS

How to use ISA95 part 3 for
MES functional URS
Jean Vieille
www.psynapses.net/vieille
<Jean Vieille>
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Agenda
•
•
•
•
What’s wrong with MES and URS?
ISA95 part 3 functional framework
Methodology
Conclusion
<Jean Vieille>
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MES: between Business and
Manufacturing
• MES is a fuzzy area:
– IT/Business community hardly understand actual manufacturing
control constraints and needs
– Control community doesn’t catch business mind,
• MES
– Crosses business processes, business tasks and control tasks
– Encompassed production, quality, maintenance, and inventory
execution control
• Not a complex technical issue
– Compared to automation: no fancy algorithmic, multipath
sequencing…
• However
– Structure requirements and assessment process takes a unique
mixture of skill sets and years of study and practice
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Example: URS vs FS in GAMP4
???
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Agenda
•
•
•
•
What’s wrong with MES and URS?
ISA95 part 3 functional framework
Methodology
Conclusion
<Jean Vieille>
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PRM + ISA95-3 functional models
1.Detailed
work
scheduling
Order
Processing
Product Cost
Accounting
Product
Shipping Admin
Production
Control
<Jean Vieille>
6. Work
analysis
4. Work
data
collection
7. Work
definition
management
3. Work
execution
Quality
Assurance
Material and
Energy Control
Maintenance
Management
5. Work
tracking
2. Work
dispatching
Product
Inventory
Control
Production
Scheduling
Procurement
8. Work
resource
management
Research
Development
& Engineering
Marketing
& Sales
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From ISA95 standards
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Combined
Order
Processing
Product Cost
Accounting
Product
Shipping Admin
Detailed
work
scheduling
Work
resource
management
Work
tracking
Work
dispatching
Production
Scheduling
Work
analysis
Work
data
collection
Work
definition
management
Work
execution
Detailed
work
scheduling
Work
resource
management
Work
tracking
Work
dispatching
Work
analysis
Detailed
work
scheduling
Detailed
work
scheduling
Work
data
collection
Work
definition
management
Work
resource
management
Work
resource
management
Work
tracking
Work
tracking
Work
execution
Work
dispatching
Work
dispatching
Work
analysis
Work
analysis
Work
data
collection
Work
definition
management
Work
data
collection
Work
definition
management
Work
execution
Work
execution
Detailed
work
scheduling
Work
resource
management
Procurement
Work
tracking
Work
dispatching
Work
analysis
Work
data
collection
Work
definition
management
Research
Development
& Engineering
Marketing
& Sales
Work
execution
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Beyond Production
• ISA95 Part 3 defines the following Manufacturing Operation
Categories (MOCs):
–
–
–
–
Production
Quality tests
Maintenance
Inventory control
• Other or different MOCs can be defined. Example:
–
–
–
–
–
Distribution, Transportation
Inbound, Outbound logistics, Internal transfers
Tooling
Cleaning
…
• It’s all about execution!
• Advanced MES solutions take care of many aspects of product
manufacturing and handling
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The ISA95 tri-dimension
functional framework
Manufacturing Operation Core
Activities
- Work Detailed Scheduling
- Work Dispatching
- Work Execution
- Work Data Collection
- Work Tracking
- Work Analysis
- Work Definition Management
- Work Resources Management
<Jean Vieille>
Manufacturing Operation Categories
- Production
- Maintenance
- Quality
- Inventory
-…
Functional Requirements
Execution/Manufacturing
Business/Planning
Supporting activities
- Management of security
- Management of information
- Management of configurations
- Management of documents
- Management of regulatory compliance
- Management of incidents and deviations
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Agenda
•
•
•
•
What’s wrong with MES and URS?
ISA95 part 3 functional framework
Methodology
Conclusion
<Jean Vieille>
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2/3Tiers Business / Execution
functional hierarchy
Business Tasks
Business Processes
(Business side)
Business Tasks
(Business related)
(S95,
MES)
Business Processes
(Execution side)
Business Tasks
(Execution related)
(S88,
Control)
<Jean Vieille>
Execution Processes
SOPs, EPEs
Work instructions
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Recipes, Routings
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URS methodology overview
URS develomment
Manufacturing
Operation
Category
Business
Processes
Activity
Task
Task
Manufacturing
Operation
Category
Business
Business
Processes Processes
Activity
Task
Task
Application Application
Component Component
Task
Task
Characterization
Application
Component
Solution adequacy & FS mapping
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General process
Phase 1:
Technical modeling
BP / Task
iteration
Phase 2:
Business Processes
Phase 3:
Tasks
Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
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Synchro
Implementation
Maintenance
Evolution
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Phase (1): Technical modeling
Step 1.1
Manufacturing Op. Categories
Phase 1:
Technical Modeling
Phase 2:
Business Processes
Phase 3:
Tasks
Step 1.2
« Material »
Resource
Step 1.3
« Equipments »
Resource
Step 1.4
« Personnel »
Resource
Step 1.5
« Working » Segments
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Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
Control
Spec and Design
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Phase (2): Business processes
• The highest functional requirement level
• They illustrate situations and tasks
(functional services) activation scenarios
• They can be manual, semi or fully
automated
• They can be hierarchic
– High level processes activate lower level
processes
– Elementary processes are tasks…
Phase 1:
Technical Modeling
Phase 2:
Business Processes
Phase 3:
Tasks
Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
• They can be compared to Manufacturing
processes : ISA88 Recipes (BP) activating
EPEs (tasks)
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Business processes
classification
Phase 1:
Technical Modeling
1. Execution management
– Work organization and execution
– MOC specific or shared
Phase 2:
Business Processes
Phase 3:
Tasks
2. Resources management
– Resources, not work related activities
3. Operations management
Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
– Dashboards, performance indicators,
activity reports not specifically linked to
work orders
4. Repository synchronization
Depend on business management options
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BPs highlight interfaces
requirements
• Some processes are shared
– Between several MOCs
– Between Business and Execution
• These situations indicates
communication links and likely
transactions.
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Phase 1:
Technical Modeling
Phase 2:
Business Processes
Phase 3:
Tasks
Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
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BPMN language
By BPMI, www.bpmi.org
Phase 1:
Technical Modeling
Phase 2:
Business Processes
Phase 3:
Tasks
Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
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Phase (3) : Tasks
Phase 2
Business processes
Phase 3
Tasks
Phase 1:
Technical Modeling
Phase 2:
Business Processes
Step 3.1
Task list
Phase 3:
Tasks
Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
Step 3.2
Description
Step 3.3
Consolidation
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Enterprise MES
Core system
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Tasks Characterization
Phase 1:
Technical Modeling
1. Physical level
6.Technical
constraints
2. Segments
7.Dependences
3. Manufacturing
Operation Categories
8. Task style
4. Responsibility
9. Justification
5. Users
10. Information
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Phase 2:
Business Processes
Phase 3:
Tasks
Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
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Tasks consolidation
Phase 1:
Technical Modeling
• Similar tasks appear in different
MOCs
• Consolidation may be possible
Phase 2:
Business Processes
Phase 3:
Tasks
Phase 4:
Solution Selection
Identical, separate
Phase 5:
Implementation Synchro
Similar,
different
MOC2
MOC1
Common
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Phase 4: Solution selection
Phase 1:
Technical Modeling
Step 4.1
Pre-qualification
Consolidated
Tasks
(phase 3)
Long
list
Step 4.2
Functional adequacy
Middle
list
Step 4.3
Mock up
Short
list
Phase 2:
Business Processes
Phase 3:
Tasks
Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
Step 4.3
Select and order
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Functional adequacy
Manufacturing Operation
MOC MOC MOC categories
Information
Functional requirements
Technical
constraints
PP
PP
P
TT
TT
T
Processes
Tasks
Users
Requirements
Application component
Solution
Standard
modules
<Jean Vieille>
Integration
Custom
development
Existing
application
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Manual
procedure
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Agenda
•
•
•
•
What’s wrong with MES and URS?
ISA95 part 3 functional framework
Methodology
Conclusion
<Jean Vieille>
Copyright © 2005 World Batch Forum
24
Conclusion
• ISA95-3 offers a robust framework
for MES requirements specification
• This makes possible to keeping
functional design in sync with URS
allowing
– Closer to expectations delivered
solution
– Consistent evolution
– Core system build up
Phase 1:
Technical Modeling
Phase 2:
Business Processes
Phase 3:
Tasks
Phase 4:
Solution Selection
Phase 5:
Implementation Synchro
However, it implies full User / Solution
integrator agreement
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