.
Practical Enterprise Modelling: ISA 88 and ISA 95 standards
IEC SB3 Sponsored Seminar Workshop on Industrial Automation Objects 34 April 2001, Geneva, Switzerland
Jean Vieille, Consultant ISA SP88 & SP95 committees member jean-vieille@usa.net
Agenda
· ISA 88 and 95 in SCM and Production Scheduling · ISA 95 : EnterpriseProduction Communication · ISA 88 : Modular Control
ISA 88 and 95 in SCM and Production Scheduling
Market / Customer driven production
Market / Customer demand
Classical Enterprise
Production Schedule
Product Development
Resources Engineering
Agile Enterprise
Market / Customer demand Production Schedule Product Develoment Production Schedule
Resources Engineering
Enterprise System 1
Manufacturing Control System 1 Manufacturing Control System 2
Company 1 with manufacturing
Enterprise System 2 Company 2 with No manufacturing
Manufacturing Control System 3 Company 3 Contract manufacturer
S95.01 Scope
Level 4
Level 3
Business Logistics Business Planning & Logistics Systems (ERP)
Plant Production Scheduling, Operational Management, etc
Interface addressed in ISA 95.01 / 02 dS95.03 Area S88
Manufacturing Operations Support Levels (MES) Batch 2,1,0 Discrete Continuous
Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...
Manufacturing Operations & Control
Control Systems
Control Systems
Control Systems
Source: ISA dS95.01 Enterprise/Control System Integration
Manufacturing in The Supply Chain
· The Supply Chain
· The network of activities in a company that take place from customer order to customer delivery
Order Entry Order Entry Suppliers Suppliers Scheduling Scheduling Suppliers Suppliers Suppliers Suppliers
Customer
Delivery Delivery
Production Production
Distribution Distribution
S95/S88 and The Supply Chain
Suppliers
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 C R R C C
Recipe Management
A
Production Planning and Scheduling
Production Information Management
E
E P
A
E P
A
Process Management
P
Order & Inventory Management
Unit Supervision
Maintenance Management
Warehouse & Transportation Management
Process Control
Process Management
Consumers
S88 et S95
Enterprise A « Product » S88 S95 Enterprise B « Product » S88
Enterprise X « Manufacturing » S88 Process Cell X1 S88 Process Cell X2
Quality
Enterprise Y « Manufacturing » S88 S88 Process Cell Y2
S95
Process Cell Y1
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
S88.02 Schedule Entry
Setup Instructions
Continuous Premix
Batch Production Discrete Process Packaging
S95 in Production System Lifecycles
Production Schedule
Segment Requirement Product Definition Product Segments Process Segments Production Capabilities
Product Development
Resources
Resources Engineering
S88 in Production System Lifecycles
Production Schedule
S88 : Schedule
S88 : Recipe S88 : Equipment Procedural Elements
S88 : Resources
Product Development
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 · Out for committee ballot and public comment · Still under development in the committee · Developing XML Schemas for the exchanged information
· ISA 95.00.02 in draft, out for vote · ISA 95.00.03 in draft · World Batch Forum
Some SP95 Committee Members / Supporters · Users
Eli Lilly Dow Corning Rohm & Haas Bayer Merck Procter&Gamble · UOP Vendors · ABB · SAP · ABB Data · Honeywell · Marcam Electric · GSE System ORSI General · Purdue · · · · · DuPont Lyondell Chemical Ben & Jerry's Novo Nordisk Sterling Tava Technologies IBM Aurora Biosciences Nestle Pharmacia Lubrizol Bechtel EastmanK Genemtech
·
AspenTech Sequencia Rockwell FRSI OSI HP IBM GS
Siemens InCode Yokogawa InCode Intellution
BaseTen Wonderware Foxboro Propack Oracle Schneider
Microsoft
·
Fluor Daniels
AMR
Jacobs
Why Did We Start SP95 ?
· Integration of business (logistics) systems to manufacturing is hard to do
· Effective operation of manufacturing is hard to do
· Different systems, cultures, terminology... · Many benefits expected from standardization and documentation of "best practices"
· MES solutions are too related to processing methods and too industryspecific · 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?
· Separate the business processes from the manufacturing processes
· Allow changes in production processes without requiring unnecessary changes scheduling and logistics processes
Alternate Logistics Strategies
Make to Order Make EngineerConfigure to to to Stock Order Order
S95.01
PDXI NAMUR S88.01 SME
Batch Discrete Continuous Manufacturing Manufacturing Manufacturing Models Models Models
· Provide a clear demarcation of responsibilities and functions · Provide a clear description of
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)
Lo Ma n t En g T Re erial a er erm cei gy pt ( nd E Re Ma Inc ner ter qu om gy ire ial ing me an ) d nt. s
Order Processing (1.0)
Fin is h e Wa d G ive ood s r
Pr od uc Ob tion Pr jec Co od tiv st uc es tio an n P d er Co fo s t rm s an ce
Product Inventory Control (7.0)
QA Res ults
Procurement (5.0)
ing n om Inc rmatio nfi Co
Maintenance Purchase Order Requirements
nd l a t.s ia er n at eme M ir rm equ e tT R or rgy Sh ne E
Production Control (3.0)
Process Data In-Process Waiver Request
Pro Standa ces s D rds ata QA Res ults
En Ma er te gy ria In l a ve nd nt or y
Quality Assurance (6.0)
Pr od uc Re Proc t an qu es d ire s me nt s
Material and Energy Control (4.0)
From ANSI/ISA95.00.011995 Copyright ISA 2000. Used with permission. www.isa.org
Research Development and Engineering
Rele a To S se hip
Pack Out Schedule
o Pr an Pl y cit om pa n Fr e l Ca io ct edu du ch S
Con fi To S rm hip
Production Scheduling (2.0)
Finished Goods Inventory
Product Cost Accounting (8.0)
Product Shipping Admin (9.0)
nd al a r teri rde Ma rgy O nts e Ene uirem q Re
s es oc Pr nd ow ta H s uc ow es od o c st Kn Pr Pr que nd e ta nR uc tio od a Pr form In
d an s rd er s da om nt an st me St Cu ire qu Re
Marketing & Sales
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 Information Information (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
Manufacturing Control Information
Major Object Definitions
Resources Capability, Product, Production
Product
People
Time
Capabilities
Equipment
Product Definitions
Materials
Production Schedule
Segments
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
l ia er at ss M la C
Material Definition HCl 50%
l ia er at ition M in f De
Lot HCL-50-100019
Sublot HCL-50-100019 Barrel 15
pH
Density
Color Purity
QA Test Results
QA Test Specification
Location
pH 7.0
Density Color Purity 1.32 Yellow .5%
Process Segments
· Business view of production
Assembly
Inspect
Paint
I-Beam Laborer 3x 8 hour Inspector 2x .25 Hour Mixing Cans Rollers Certified Painter = TRUE
Type = Stainless Steel
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
Time
Capabilities
Equipment
Materials
Segments
Per Product Definitions
Scheduling System
Bill Of Resources e.g. 10 Speed Bicycle
f O ill rces B u so Re
Material System
Bill Of Materials e.g. 10 Speed Bicycle Product Segments
ll Bi f O er at M ls ia
Frame Assembly
Final Assembly
Paint
Production Rules e.g. 10 Speed Bicycle
y bl em ions s As ruct st In
Color Frame Type Seat Height
Manufacturing System
Manufacturing Bill Frame : 1 Wheels : 2 Chain : 1 Seat : 1 Handlebars :1 Brake Pads : 4 ...
Production Schedule
People
Equipment
Product Definitions
Materials
Production Schedule
Segments
Production Performance
People
Equipment
Product Definitions
Materials
Production Schedule
Segments
Production Performance
Four Models & Segment Resources
Production Capability
What resources are available
Process Specification
What can be done with the resources
Product Definition
What must be defined to make a product
Production Scheduling
What is it to be made & used
Production Information
What was made & used
Production Schedule Production Rule Production Capability
Resource Capability
Production Performance Production Response Segment Response
Resource Actual
Production Request Segment Requirement
Resource Requirement
Process Segment
Resource Segment Capability
Product Segment
Resource Specification
Capability Property
Segment Property
Specification Property
Requirement Property
Actual Property
ISA 95.00.02 : Relationship with Part 1
ISA95.01
Equipment model
dISA95.02
Equipment Attributes
Attribute Name
Description
Examples
ID
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
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
Detailed Production Scheduling
Production Performance
Resource Management Production Dispatching
Product Definition Management
Production Tracking (QA) Product Analysis
Historical Data Management
Process Analysis Production Analysis
Production Execution Process Monitoring Automated Control
Manual Operations
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 615121 bilingue disponible auprès de l'IEC, l'UTE et l'AFNOR · Publication imminente · Version IEC (615122) bilingue pour 2001? · Début des travaux
· Partie 2 ISA 88.00.02
· Partie 3 ISA 88.00.03
Automation Challenge
Ideal automation
Flexibility
S88
Manual Operation
Capability
Darin Flemming Lou Pillai
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 The Goal: I know What/How To do Process Control Definition Equipment Functional Capabilities Elementary Equipment Control
Flying chirping Eating Love.
Walking
Scheduling hierarchy
Business system ISA 95 MES systems SCADA systems ISA 88 IEC 61512 OPC
Process Control
Equipment Control
IEC 61131 IEC 61499 IEC 61158 Fieldbus
« Intelligent » Device
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 ?
IEC 60848 IEC 61131 IEC 61499 IEC 61508 IEC61158
ISA 88
R&D
ISA 88.00.02 (PFC)
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 EM CM CM CM CM CM CM EM EM Unit
Example of control modules
CM4
CM2 CM1 D1 PID D3
D4 PID PID CM3 D5 D2 HIC HIC
Why Control Modules
Treating as a control module simplifies the interface to this group of objects
Commands
Circulate Pump to Process Stop Shutdown
Pump FO
Status
Circulating Pumping to Process Stopped Shutdown
FC
Recipe/Equipment Control Separation
Control Recipe Procedure
Recipe Procedure Procedure
is an ordered set of
Equipment Control
[Must Always Exist]
Unit Procedure
is an ordered set of
Operation
is an ordered set of
Phase
Equipment Phase
Recipe/Equipment Control Separation - Typical
Control Recipe Procedure
Recipe Procedure
is an ordered set of
Equipment Control
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
Control Recipe Procedure
Recipe Procedure References
Equipment Control
Equipment Procedure
is an ordered set of
Equip. Unit Procedure
is an ordered set of
Equipment Operation Equipment Phase
is an ordered set of
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
Parameters Requests
Commands
State Machine
States
Phase Object
Parameters Start Hold Pause Stop Abort Reset Resume Restart Aborting Pausing Data Run Held Paused Stopped Aborted Data Collection Requirements Idle Completed
Holding
Running
Stopping
Control Action Status
Restarting Control Steps
Example Procedural Element States
Restart Complete Reset Hold Idle (Initial State) Start Running Abort Stop Aborting Stopping Pause Resume Paused Pausing Restarting Held Holding
Aborted Reset
Stopped Reset
Final States 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 Process Interlock
Control Module
Exception Logic
Control Module
The process interlock logic takes precedence over phase logic and manual override logic. Typically, this logic is implemented in the DPCS.
Phase Logic
Equipment Module
Control step (command)
Control Action
Field I/O
Control Module
Control Module/Control Action State/Mode
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 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
Tank A, B or C
· Relative timing
P r e p a r a tio n
S1
R e a c to r 1 or 2 o p e r a to r in p u t = O K to s ta rt
R e a c tio n
S1
T1
T1
· Synchronization points · Multiple levels of procedures
· Height of unit procedure symbol · Vertical placement of symbols · Master recipes do not contain absolute timing · Arrowheads indicate material transfer · Encapsulation (contents) of unit procedure revealed
THANK YOU
IEC SB3 Sponsored Seminar Workshop on Industrial Automation Objects 34 April 2001, Geneva, Switzerland
Jean Vieille, Consultant ISA SP88 & SP95 committees member jean-vieille@usa.net
Agenda
· ISA 88 and 95 in SCM and Production Scheduling · ISA 95 : EnterpriseProduction Communication · ISA 88 : Modular Control
ISA 88 and 95 in SCM and Production Scheduling
Market / Customer driven production
Market / Customer demand
Classical Enterprise
Production Schedule
Product Development
Resources Engineering
Agile Enterprise
Market / Customer demand Production Schedule Product Develoment Production Schedule
Resources Engineering
Enterprise System 1
Manufacturing Control System 1 Manufacturing Control System 2
Company 1 with manufacturing
Enterprise System 2 Company 2 with No manufacturing
Manufacturing Control System 3 Company 3 Contract manufacturer
S95.01 Scope
Level 4
Level 3
Business Logistics Business Planning & Logistics Systems (ERP)
Plant Production Scheduling, Operational Management, etc
Interface addressed in ISA 95.01 / 02 dS95.03 Area S88
Manufacturing Operations Support Levels (MES) Batch 2,1,0 Discrete Continuous
Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...
Manufacturing Operations & Control
Control Systems
Control Systems
Control Systems
Source: ISA dS95.01 Enterprise/Control System Integration
Manufacturing in The Supply Chain
· The Supply Chain
· The network of activities in a company that take place from customer order to customer delivery
Order Entry Order Entry Suppliers Suppliers Scheduling Scheduling Suppliers Suppliers Suppliers Suppliers
Customer
Delivery Delivery
Production Production
Distribution Distribution
S95/S88 and The Supply Chain
Suppliers
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 C R R C C
Recipe Management
A
Production Planning and Scheduling
Production Information Management
E
E P
A
E P
A
Process Management
P
Order & Inventory Management
Unit Supervision
Maintenance Management
Warehouse & Transportation Management
Process Control
Process Management
Consumers
S88 et S95
Enterprise A « Product » S88 S95 Enterprise B « Product » S88
Enterprise X « Manufacturing » S88 Process Cell X1 S88 Process Cell X2
Quality
Enterprise Y « Manufacturing » S88 S88 Process Cell Y2
S95
Process Cell Y1
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
S88.02 Schedule Entry
Setup Instructions
Continuous Premix
Batch Production Discrete Process Packaging
S95 in Production System Lifecycles
Production Schedule
Segment Requirement Product Definition Product Segments Process Segments Production Capabilities
Product Development
Resources
Resources Engineering
S88 in Production System Lifecycles
Production Schedule
S88 : Schedule
S88 : Recipe S88 : Equipment Procedural Elements
S88 : Resources
Product Development
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 · Out for committee ballot and public comment · Still under development in the committee · Developing XML Schemas for the exchanged information
· ISA 95.00.02 in draft, out for vote · ISA 95.00.03 in draft · World Batch Forum
Some SP95 Committee Members / Supporters · Users
Eli Lilly Dow Corning Rohm & Haas Bayer Merck Procter&Gamble · UOP Vendors · ABB · SAP · ABB Data · Honeywell · Marcam Electric · GSE System ORSI General · Purdue · · · · · DuPont Lyondell Chemical Ben & Jerry's Novo Nordisk Sterling Tava Technologies IBM Aurora Biosciences Nestle Pharmacia Lubrizol Bechtel EastmanK Genemtech
·
AspenTech Sequencia Rockwell FRSI OSI HP IBM GS
Siemens InCode Yokogawa InCode Intellution
BaseTen Wonderware Foxboro Propack Oracle Schneider
Microsoft
·
Fluor Daniels
AMR
Jacobs
Why Did We Start SP95 ?
· Integration of business (logistics) systems to manufacturing is hard to do
· Effective operation of manufacturing is hard to do
· Different systems, cultures, terminology... · Many benefits expected from standardization and documentation of "best practices"
· MES solutions are too related to processing methods and too industryspecific · 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?
· Separate the business processes from the manufacturing processes
· Allow changes in production processes without requiring unnecessary changes scheduling and logistics processes
Alternate Logistics Strategies
Make to Order Make EngineerConfigure to to to Stock Order Order
S95.01
PDXI NAMUR S88.01 SME
Batch Discrete Continuous Manufacturing Manufacturing Manufacturing Models Models Models
· Provide a clear demarcation of responsibilities and functions · Provide a clear description of
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)
Lo Ma n t En g T Re erial a er erm cei gy pt ( nd E Re Ma Inc ner ter qu om gy ire ial ing me an ) d nt. s
Order Processing (1.0)
Fin is h e Wa d G ive ood s r
Pr od uc Ob tion Pr jec Co od tiv st uc es tio an n P d er Co fo s t rm s an ce
Product Inventory Control (7.0)
QA Res ults
Procurement (5.0)
ing n om Inc rmatio nfi Co
Maintenance Purchase Order Requirements
nd l a t.s ia er n at eme M ir rm equ e tT R or rgy Sh ne E
Production Control (3.0)
Process Data In-Process Waiver Request
Pro Standa ces s D rds ata QA Res ults
En Ma er te gy ria In l a ve nd nt or y
Quality Assurance (6.0)
Pr od uc Re Proc t an qu es d ire s me nt s
Material and Energy Control (4.0)
From ANSI/ISA95.00.011995 Copyright ISA 2000. Used with permission. www.isa.org
Research Development and Engineering
Rele a To S se hip
Pack Out Schedule
o Pr an Pl y cit om pa n Fr e l Ca io ct edu du ch S
Con fi To S rm hip
Production Scheduling (2.0)
Finished Goods Inventory
Product Cost Accounting (8.0)
Product Shipping Admin (9.0)
nd al a r teri rde Ma rgy O nts e Ene uirem q Re
s es oc Pr nd ow ta H s uc ow es od o c st Kn Pr Pr que nd e ta nR uc tio od a Pr form In
d an s rd er s da om nt an st me St Cu ire qu Re
Marketing & Sales
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 Information Information (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
Manufacturing Control Information
Major Object Definitions
Resources Capability, Product, Production
Product
People
Time
Capabilities
Equipment
Product Definitions
Materials
Production Schedule
Segments
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
l ia er at ss M la C
Material Definition HCl 50%
l ia er at ition M in f De
Lot HCL-50-100019
Sublot HCL-50-100019 Barrel 15
pH
Density
Color Purity
QA Test Results
QA Test Specification
Location
pH 7.0
Density Color Purity 1.32 Yellow .5%
Process Segments
· Business view of production
Assembly
Inspect
Paint
I-Beam Laborer 3x 8 hour Inspector 2x .25 Hour Mixing Cans Rollers Certified Painter = TRUE
Type = Stainless Steel
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
Time
Capabilities
Equipment
Materials
Segments
Per Product Definitions
Scheduling System
Bill Of Resources e.g. 10 Speed Bicycle
f O ill rces B u so Re
Material System
Bill Of Materials e.g. 10 Speed Bicycle Product Segments
ll Bi f O er at M ls ia
Frame Assembly
Final Assembly
Paint
Production Rules e.g. 10 Speed Bicycle
y bl em ions s As ruct st In
Color Frame Type Seat Height
Manufacturing System
Manufacturing Bill Frame : 1 Wheels : 2 Chain : 1 Seat : 1 Handlebars :1 Brake Pads : 4 ...
Production Schedule
People
Equipment
Product Definitions
Materials
Production Schedule
Segments
Production Performance
People
Equipment
Product Definitions
Materials
Production Schedule
Segments
Production Performance
Four Models & Segment Resources
Production Capability
What resources are available
Process Specification
What can be done with the resources
Product Definition
What must be defined to make a product
Production Scheduling
What is it to be made & used
Production Information
What was made & used
Production Schedule Production Rule Production Capability
Resource Capability
Production Performance Production Response Segment Response
Resource Actual
Production Request Segment Requirement
Resource Requirement
Process Segment
Resource Segment Capability
Product Segment
Resource Specification
Capability Property
Segment Property
Specification Property
Requirement Property
Actual Property
ISA 95.00.02 : Relationship with Part 1
ISA95.01
Equipment model
dISA95.02
Equipment Attributes
Attribute Name
Description
Examples
ID
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
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
Detailed Production Scheduling
Production Performance
Resource Management Production Dispatching
Product Definition Management
Production Tracking (QA) Product Analysis
Historical Data Management
Process Analysis Production Analysis
Production Execution Process Monitoring Automated Control
Manual Operations
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 615121 bilingue disponible auprès de l'IEC, l'UTE et l'AFNOR · Publication imminente · Version IEC (615122) bilingue pour 2001? · Début des travaux
· Partie 2 ISA 88.00.02
· Partie 3 ISA 88.00.03
Automation Challenge
Ideal automation
Flexibility
S88
Manual Operation
Capability
Darin Flemming Lou Pillai
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 The Goal: I know What/How To do Process Control Definition Equipment Functional Capabilities Elementary Equipment Control
Flying chirping Eating Love.
Walking
Scheduling hierarchy
Business system ISA 95 MES systems SCADA systems ISA 88 IEC 61512 OPC
Process Control
Equipment Control
IEC 61131 IEC 61499 IEC 61158 Fieldbus
« Intelligent » Device
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 ?
IEC 60848 IEC 61131 IEC 61499 IEC 61508 IEC61158
ISA 88
R&D
ISA 88.00.02 (PFC)
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 EM CM CM CM CM CM CM EM EM Unit
Example of control modules
CM4
CM2 CM1 D1 PID D3
D4 PID PID CM3 D5 D2 HIC HIC
Why Control Modules
Treating as a control module simplifies the interface to this group of objects
Commands
Circulate Pump to Process Stop Shutdown
Pump FO
Status
Circulating Pumping to Process Stopped Shutdown
FC
Recipe/Equipment Control Separation
Control Recipe Procedure
Recipe Procedure Procedure
is an ordered set of
Equipment Control
[Must Always Exist]
Unit Procedure
is an ordered set of
Operation
is an ordered set of
Phase
Equipment Phase
Recipe/Equipment Control Separation - Typical
Control Recipe Procedure
Recipe Procedure
is an ordered set of
Equipment Control
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
Control Recipe Procedure
Recipe Procedure References
Equipment Control
Equipment Procedure
is an ordered set of
Equip. Unit Procedure
is an ordered set of
Equipment Operation Equipment Phase
is an ordered set of
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
Parameters Requests
Commands
State Machine
States
Phase Object
Parameters Start Hold Pause Stop Abort Reset Resume Restart Aborting Pausing Data Run Held Paused Stopped Aborted Data Collection Requirements Idle Completed
Holding
Running
Stopping
Control Action Status
Restarting Control Steps
Example Procedural Element States
Restart Complete Reset Hold Idle (Initial State) Start Running Abort Stop Aborting Stopping Pause Resume Paused Pausing Restarting Held Holding
Aborted Reset
Stopped Reset
Final States 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 Process Interlock
Control Module
Exception Logic
Control Module
The process interlock logic takes precedence over phase logic and manual override logic. Typically, this logic is implemented in the DPCS.
Phase Logic
Equipment Module
Control step (command)
Control Action
Field I/O
Control Module
Control Module/Control Action State/Mode
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 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
Tank A, B or C
· Relative timing
P r e p a r a tio n
S1
R e a c to r 1 or 2 o p e r a to r in p u t = O K to s ta rt
R e a c tio n
S1
T1
T1
· Synchronization points · Multiple levels of procedures
· Height of unit procedure symbol · Vertical placement of symbols · Master recipes do not contain absolute timing · Arrowheads indicate material transfer · Encapsulation (contents) of unit procedure revealed
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