.
How to use ISA95 part 3 for MES functional URS
Jean Vieille www.psynapses.net/vieille
<Jean Vieille>
Copyright © 2005 World Batch Forum
1
Agenda
· · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion
<Jean Vieille>
Copyright © 2005 World Batch 2 Forum
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
<Jean Vieille>
Copyright © 2005 World Batch 3 Forum
Example: URS vs FS in GAMP4
???
<Jean Vieille>
Copyright © 2005 World Batch 4 Forum
Agenda
· · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion
<Jean Vieille>
Copyright © 2005 World Batch 5 Forum
PRM + ISA95-3 functional models
1.Detailed work scheduling 8. Work resource management 2. Work dispatching 7. Work definition management 3. Work execution 4. Work data collection 5. Work tracking 6. Work analysis
Order Processing
Product Cost Accounting
Product Shipping Admin
Production Scheduling
Product Inventory Control
Production Control Material and Energy Control
Quality Assurance
Procurement
Maintenance Management
Research Development & Engineering
Marketing & Sales
From ISA95 standards
<Jean Vieille>
Copyright © 2005 World Batch 6 Forum
Combined
Order Processing Product Cost Accounting Product Shipping Admin
Detailed work scheduling
Work resource management
Work tracking
Production Scheduling
Work dispatching
Work analysis
Work definition management
Work data collection
Work execution
Detailed work scheduling
Work resource management
Work tracking
Work dispatching
Work analysis Detailed work scheduling
Detailed work scheduling
Work definition management
Work data collection Work resource management Work tracking
Work resource management
Work tracking
Work execution
Work dispatching
Work analysis
Work dispatching
Work analysis
Work definition management
Work data collection
Work definition management
Work data collection
Work execution
Work execution
Detailed work scheduling
Work resource management
Work tracking
Procurement
Work definition management
Work dispatching
Work analysis
Work data collection
Research Development & Engineering
Marketing & Sales
Work execution
<Jean Vieille>
Copyright © 2005 World Batch 7 Forum
Beyond Production
· ISA95 Part 3 defines the following Manufacturing Categories (MOCs):
Production Quality tests Maintenance Inventory control Distribution, Transportation Inbound, Outbound logistics, Internal transfers Tooling Cleaning ...
Operation
·
Other or different MOCs can be defined. Example:
· ·
It's all about execution! Advanced MES solutions take care of many aspects of product manufacturing and handling
<Jean Vieille>
Copyright © 2005 World Batch 8 Forum
The ISA95 tri-dimension functional framework
Manufacturing Operation Categories Production Maintenance Quality Inventory ...
Manufacturing Operation Core Activities Work Detailed Scheduling Work Dispatching Work Execution Work Data Collection Work Tracking Work Analysis Work Definition Management Work Resources Management
Functional Requirements
Execution/Manufacturing Business/Planning
<Jean Vieille>
Copyright
Supporting activities Management of security Management of information Management of configurations Management of documents Management of regulatory compliance Management of incidents and deviations World Batch 9 © 2005 Forum
Agenda
· · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion
<Jean Vieille>
Copyright © 2005 World Batch 10 Forum
2/3Tiers Business / Execution functional hierarchy
Business Tasks
Business Processes
(Business side) Business Tasks
(Business related)
Business Processes
(Execution side) Business Tasks
(Execution related)
(S95, MES)
(S88, Control)
<Jean Vieille>
SOPs, EPEs Work instructions
Execution Processes
Recipes, Routings
Copyright © 2005 World Batch 11 Forum
URS methodology overview
Manufacturing Operation Category Business Processes Activity Activity Manufacturing Operation Category Business Business Processes Processes
Task
Task
Task
Task
Task
Task
Characterization
t ne mml ev ed S RU o
Application Application Component Component
Application Component
Solution adequacy & FS mapping
<Jean Vieille>
Copyright © 2005 World Batch 12 Forum
General process
Phase 1: Technical modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
<Jean Vieille>
BP / Task iteration
Synchro
Implementation Maintenance Evolution
Copyright © 2005 World Batch 13 Forum
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
Phase 4: Solution Selection Phase 5: Implementation Synchro
Step 1.5 « Working » Segments
<Jean Vieille>
Control Spec and Design
Copyright © 2005 World Batch 14 Forum
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)
<Jean Vieille>
Copyright © 2005 World Batch 15 Forum
Business processes classification
1. Execution management
Work organization and execution MOC specific or shared
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
2. Resources management
Resources, not work related activities
3. Operations management
Dashboards, performance indicators, activity reports not specifically linked to work orders
4. Repository synchronization Depend on business management options
<Jean Vieille>
Copyright © 2005 World Batch 16 Forum
BPs highlight interfaces requirements
· Some processes are shared
Between several MOCs Between Business and Execution
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
· These situations indicates communication links and likely transactions.
<Jean Vieille>
Copyright © 2005 World Batch 17 Forum
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
<Jean Vieille>
Copyright © 2005 World Batch 18 Forum
Phase (3) : Tasks
Phase 2 Business processes Phase 3 Tasks
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
Step 3.1 Task list
Step 3.2 Description
Step 3.3 Consolidation
Enterprise MES Core system
<Jean Vieille>
Copyright © 2005 World Batch 19 Forum
Tasks Characterization
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
1. Physical level 2. Segments 3. Manufacturing Operation Categories 4. Responsibility 5. Users
6.Technical constraints 7.Dependences 8. Task style 9. Justification 10. Information
<Jean Vieille>
Copyright © 2005 World Batch 20 Forum
Tasks consolidation
· Similar tasks appear in different MOCs · Consolidation may be possible
Identical, separate
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
Similar, different MOC1 Common MOC2
<Jean Vieille>
Copyright © 2005 World Batch 21 Forum
Phase 4: Solution selection
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
Step 4.1 Pre-qualification
Long list Middle list Short list
Consolidated Tasks (phase 3)
Step 4.2 Functional adequacy Step 4.3 Mock up Step 4.3 Select and order
<Jean Vieille>
Copyright © 2005 World Batch 22 Forum
Functional adequacy
Information Technical constraints
Manufacturing Operation MOC MOC MOC categories
Functional requirements PP PP P
Processes
Users
TT TT T
Tasks
Requirements Application component Solution Standard modules
<Jean Vieille>
Integration
Custom development
Existing application
Manual procedure
Copyright © 2005 World Batch 23 Forum
Agenda
· · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion
<Jean Vieille>
Copyright © 2005 World Batch 24 Forum
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
<Jean Vieille>
Copyright © 2005 World Batch 25 Forum
Jean Vieille www.psynapses.net/vieille
<Jean Vieille>
Copyright © 2005 World Batch Forum
1
Agenda
· · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion
<Jean Vieille>
Copyright © 2005 World Batch 2 Forum
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
<Jean Vieille>
Copyright © 2005 World Batch 3 Forum
Example: URS vs FS in GAMP4
???
<Jean Vieille>
Copyright © 2005 World Batch 4 Forum
Agenda
· · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion
<Jean Vieille>
Copyright © 2005 World Batch 5 Forum
PRM + ISA95-3 functional models
1.Detailed work scheduling 8. Work resource management 2. Work dispatching 7. Work definition management 3. Work execution 4. Work data collection 5. Work tracking 6. Work analysis
Order Processing
Product Cost Accounting
Product Shipping Admin
Production Scheduling
Product Inventory Control
Production Control Material and Energy Control
Quality Assurance
Procurement
Maintenance Management
Research Development & Engineering
Marketing & Sales
From ISA95 standards
<Jean Vieille>
Copyright © 2005 World Batch 6 Forum
Combined
Order Processing Product Cost Accounting Product Shipping Admin
Detailed work scheduling
Work resource management
Work tracking
Production Scheduling
Work dispatching
Work analysis
Work definition management
Work data collection
Work execution
Detailed work scheduling
Work resource management
Work tracking
Work dispatching
Work analysis Detailed work scheduling
Detailed work scheduling
Work definition management
Work data collection Work resource management Work tracking
Work resource management
Work tracking
Work execution
Work dispatching
Work analysis
Work dispatching
Work analysis
Work definition management
Work data collection
Work definition management
Work data collection
Work execution
Work execution
Detailed work scheduling
Work resource management
Work tracking
Procurement
Work definition management
Work dispatching
Work analysis
Work data collection
Research Development & Engineering
Marketing & Sales
Work execution
<Jean Vieille>
Copyright © 2005 World Batch 7 Forum
Beyond Production
· ISA95 Part 3 defines the following Manufacturing Categories (MOCs):
Production Quality tests Maintenance Inventory control Distribution, Transportation Inbound, Outbound logistics, Internal transfers Tooling Cleaning ...
Operation
·
Other or different MOCs can be defined. Example:
· ·
It's all about execution! Advanced MES solutions take care of many aspects of product manufacturing and handling
<Jean Vieille>
Copyright © 2005 World Batch 8 Forum
The ISA95 tri-dimension functional framework
Manufacturing Operation Categories Production Maintenance Quality Inventory ...
Manufacturing Operation Core Activities Work Detailed Scheduling Work Dispatching Work Execution Work Data Collection Work Tracking Work Analysis Work Definition Management Work Resources Management
Functional Requirements
Execution/Manufacturing Business/Planning
<Jean Vieille>
Copyright
Supporting activities Management of security Management of information Management of configurations Management of documents Management of regulatory compliance Management of incidents and deviations World Batch 9 © 2005 Forum
Agenda
· · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion
<Jean Vieille>
Copyright © 2005 World Batch 10 Forum
2/3Tiers Business / Execution functional hierarchy
Business Tasks
Business Processes
(Business side) Business Tasks
(Business related)
Business Processes
(Execution side) Business Tasks
(Execution related)
(S95, MES)
(S88, Control)
<Jean Vieille>
SOPs, EPEs Work instructions
Execution Processes
Recipes, Routings
Copyright © 2005 World Batch 11 Forum
URS methodology overview
Manufacturing Operation Category Business Processes Activity Activity Manufacturing Operation Category Business Business Processes Processes
Task
Task
Task
Task
Task
Task
Characterization
t ne mml ev ed S RU o
Application Application Component Component
Application Component
Solution adequacy & FS mapping
<Jean Vieille>
Copyright © 2005 World Batch 12 Forum
General process
Phase 1: Technical modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
<Jean Vieille>
BP / Task iteration
Synchro
Implementation Maintenance Evolution
Copyright © 2005 World Batch 13 Forum
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
Phase 4: Solution Selection Phase 5: Implementation Synchro
Step 1.5 « Working » Segments
<Jean Vieille>
Control Spec and Design
Copyright © 2005 World Batch 14 Forum
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)
<Jean Vieille>
Copyright © 2005 World Batch 15 Forum
Business processes classification
1. Execution management
Work organization and execution MOC specific or shared
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
2. Resources management
Resources, not work related activities
3. Operations management
Dashboards, performance indicators, activity reports not specifically linked to work orders
4. Repository synchronization Depend on business management options
<Jean Vieille>
Copyright © 2005 World Batch 16 Forum
BPs highlight interfaces requirements
· Some processes are shared
Between several MOCs Between Business and Execution
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
· These situations indicates communication links and likely transactions.
<Jean Vieille>
Copyright © 2005 World Batch 17 Forum
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
<Jean Vieille>
Copyright © 2005 World Batch 18 Forum
Phase (3) : Tasks
Phase 2 Business processes Phase 3 Tasks
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
Step 3.1 Task list
Step 3.2 Description
Step 3.3 Consolidation
Enterprise MES Core system
<Jean Vieille>
Copyright © 2005 World Batch 19 Forum
Tasks Characterization
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
1. Physical level 2. Segments 3. Manufacturing Operation Categories 4. Responsibility 5. Users
6.Technical constraints 7.Dependences 8. Task style 9. Justification 10. Information
<Jean Vieille>
Copyright © 2005 World Batch 20 Forum
Tasks consolidation
· Similar tasks appear in different MOCs · Consolidation may be possible
Identical, separate
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
Similar, different MOC1 Common MOC2
<Jean Vieille>
Copyright © 2005 World Batch 21 Forum
Phase 4: Solution selection
Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro
Step 4.1 Pre-qualification
Long list Middle list Short list
Consolidated Tasks (phase 3)
Step 4.2 Functional adequacy Step 4.3 Mock up Step 4.3 Select and order
<Jean Vieille>
Copyright © 2005 World Batch 22 Forum
Functional adequacy
Information Technical constraints
Manufacturing Operation MOC MOC MOC categories
Functional requirements PP PP P
Processes
Users
TT TT T
Tasks
Requirements Application component Solution Standard modules
<Jean Vieille>
Integration
Custom development
Existing application
Manual procedure
Copyright © 2005 World Batch 23 Forum
Agenda
· · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion
<Jean Vieille>
Copyright © 2005 World Batch 24 Forum
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
<Jean Vieille>
Copyright © 2005 World Batch 25 Forum
Johann Sebastian Bach. the music closest to silence, closest, in spite of its being so highly organized, to pure, one-hundred-degree proof Spirit" (Aldous Huxley, Island)