District 12 & Qatar Section ISA-95/B2MML Tutorial: Integration practice from use cases to xml messages Jean Vieille Standards Certification Education & Training Publishing Conferences & Exhibits j.vieille@controlchaingroup.com www.syntropicfactory.com www.controlchaingroup.net ISA Automation Conference ­ Doha (Qatar) - 9 & 10 December 2012 Introduction · This tutorial will first present successively: ­ A practical example of a fictitious industrial company to grasp basics of modeling patterns and interoperability realm of ISA-95 as well as B2MML messages content ­ A methodology for specifying information flows ­ The models from the recently updated ISA-95 part 2 and 4. ­ The standard information services defined in ISA-95 part 5 ­ The structure of the XML messages based on B2MML 2 Introduction · Objective : ­ A quick overview of interoperability related ISA-95 parts ­ be prepared to address integration between different manufacturing applications (ERP, control systems, MES, FCS, LIMS, CMMS...) in a consistent, efficient and documented manner. · Participants ­ Industrial IT managers ­ Project managers for integration ­ Functional analysts involved in cross systems (i.e.ERP, MES, SCADA) business processes 3 Agenda · · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML 4 Objectives · This section exemplifies ISA-95 usage for ­ describing manufacturing facilities and operations ­ Exchanging related information · The different aspects of a fancy company and product serve as a basis for illustrating ­ ­ ­ ­ Product industrialization Involved facilities Production planning Production reporting · It makes use of simplified ISA95 UML models and B2MML textual representation 5 Agenda · Example ­ ­ ­ ­ Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance · · · · Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML 6 Products and Production organisation · Understanding of product structure ­ Manufacturing stages ­ Their relationships · Outline the manufacturing strategy ­ In-house manufacturing, mono/multi process cells- Sites ­ Synchronized contract manufacturing ­ Purchasing · Introduce Production definition, product segment 7 Product · SuperToner ­ The world's first wireless Internet enabled laser printer cartridges · Products are available for a selection of printers HP, Epson, Brother and Canon · Manufactured in 3 plants located in USA · The process includes the following stages: ­ ­ ­ ­ ­ Plastic molding Electronic board assembly for wireless connexion Printing ink manufacturing Assembly, filling and test Customizable packaging 8 Bill Of Material - Top Level Items Printer Cartridge Ink Refill Wireless Ethernet Sensor & Module Customized Returnable Shipping Box 9 General product manufacturing structure Cartridge top level product segments Plastic enclosure manufacturing Electronic board manufacturing Ink manufacturing Other parts Manufactured Purchased Assembly 10 Manufactured items Enclosure Product Segments Plastic making Body Molding Cover Molding Finishing Pre-assembling Ink Product Segments Reaction Sieving Refining Conditionning Electronic Board Product Segments Engraving drilling Mounting Testing 11 Assembly Assembly Product Segments Assembling Filling Print Test Wireless test Packaging 12 Product segment structure Cartridge S1 S2 S3 S4 Enclosure Ink Electronic board Assembly S1 Enclosure S1.1 Plastic making S1.2 Body molding S1.3 Cover molding S1.4 Finishing ­ Preassembling S2 Ink S2.1 Reaction S2.2 Sieving S2.3 Refining S2.4 Conditionning S4 Assembly S4.1 S4.2 S4.3 S4.4 S4.5 Assembling Filling Print test Wireless test Packing S3 Electronic board S3.1 S3.2 S3.3 S3.4 Engraving Drilling Mounting Testing 13 Product Families and variants Families (one dimension) F1 Separable drum F2 Embedded drum Variants (multidimensional) V1 1 Canon Packing 2 HP Packing 3 Epson Packing V2 1 TN6600 OEM model 2 HX2200 OEM model 14 Simple manufacturing model Super Toner Plastic molding production line Suppliers Electronic board assembly Production line Ink manufacturing Process cell Assembly & Test Production Line Customers 15 Cooperative manufacturing model SuperToner Cartridge Manufacturer Suppliers Plastic molding & Assembly Plant Customers Suppliers Company B Electronic subcontractor Company C Ink subcontractor Suppliers 16 Product segment allocation SuperToner S1: Make Enclosure S1.1 Plastic making S1.2 Body molding S1.3 Cover molding S1.4 Finishing ­ Pre-assembling Company C S2: Make Ink S2.1 Reaction S2.2 Sieving S2.3 Refining S2.4 Conditionning S4: Make Assembly S4.1 Assembling S4.2 Filling S4.3 Print test S4.4 Wireless test S4.5 Packing Company B S3: Make Electronic board S3.1 Engraving S3.2 Drilling S3.3 Mounting S3.4 Testing 17 Operations definition model Operations Definition May be made up of Has 1..n associated Segment dependency 0..n Parameter 0..n Operations Segment 0..n Equipment Specification Must correspond to element in 0..n Personnel Specification Must correspond to element in 0..n Material Specification Must correspond to element in Equipment Model Personnel Model Material Model 18 B2MML: Product Information ­ 1st level product segments F2 Embedded drum toner cartridges Production 2012-12-08 TN6600 V0 For Brother HL series TN6600 S1 Make Enclosure < OperationsSegment > S2 Make Ink 19 B2MML : 2nd level product segments < OperationsSegment > S1.2 Body molding 1 H multi-mold workcell Body+cover molding Before S1.4 MoldReference M6600 Molder 1 Polyethylen P22 Rigid Polymer Consumed 234 G 20 Agenda · Example ­ ­ ­ ­ Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance · · · · Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML 21 Resources · Identify the resources organisation: ­ ­ ­ ­ Personnel Equipments Material & Energy Process Segments 22 Available resources: Equipment SuperToner Equipment Manufacturer Molding Line1 Molding Machine 1 Molding Machine 2 Molding Machine 3 Company B Electronic sub-contractor Company C Ink sub-contractor Solid Ink Pcell Liquid Ink Pcell Blending Unit Molding Line2 Molding Machine 4 Molding Machine 5 Engraving Unit Drilling Machine Mounting WkCell Testing WkCell Reactor Unit Sieving & refining Unit Conditionning Line WkCell 1 WkCell 2 Assembly Line WkCell 1 WkCell 2 WkCell 3 23 Available resources (at SuperToner plant) Material Material Def. P22 P56 ECPH WLS25 Kit345 Class Polyethylen Polyethylen Ink Electronic board Accessories Lot PY2702 PY2906 E456 W1257 L35123 Qté 125 kg 54 kg 253 kg 49 56 Classe Molder Molder Molder Assembler Assembler Assembler Printing Tester Electronic Tester Lev. 1 1 2 Equipment ID Equipt E1 Machine1 E2 Machine2 E3 Machine3 E4 Machine4 E5 Machine5 E6 WkCell1 E7 WkCell2 E8 WkCell3 Classe Single molding Single molding Single molding Double molding Double molding Assembly station Assembly station Assembly station Personnel ID Name P1 Albert P2 Bob P3 Chris P4 David P5 Eric P6 Francis P7 Greg P8 John 24 Personnel model 0..n 0..n Defined by Personnel Class Has properties Of Person Has values for 0..n Must map To 0..n Personnel Class Property Person Property 25 B2MML : Personnel Personnel of SuperToner 2012-12-08 Molder Molder MolderQualif Molder Qualification test 1 or 2 TestLevel P1 Albert Molder MolderQualif 1 Pass 26 Process Segment Concept Personnel resources managed for production People Equipment resources managed for production Equipment Material resources managed for production Materials Collections of resources, used together for production, at the granularity needed for business level scheduling and costing Segments 27 Available Resources : Process Segments Id Sa1 Process Segment Body molding Cover molding Body + cover molding finishing + pre assembly Personnel Class 1 molder Duration=1 H 1 molder Duration= 1H 1 molder Level=2 Duration= 1H 1 assembler Duration= 30' Equipment Class Material Class Parameters MoldReference =M* MoldReference =M* MoldReference =M* Single mold mach. Polyethyle n Duration= 1H Q=? Single mold mach. Q=? Duration= 1H Double mold mach. Duration= 1H Assembly worlkstation Duration= 30' Q=? Sa2 Sa3 Sa4 ECPH Q=1 WLS25 Q=1 28 Process Segment model 0..n May be Made up of 0..n 0..n Process Segment Segment dependency 0..n 0..n 0..n 0..n Parameter Equipment Specification Personnel Specification Material Specification corresponds to element in corresponds to element in corresponds to element in Equipment Model Personnel Model Material Model 29 B2MML : Process Segments Available processes definition SuperToner / Site 2012-12-08 Sa1 Body molding 1 H Molder Single mold. Mach. Polyethylen MoldReference M* 30 Production Capability · Resources are now identified · We have to provide information about allocation and availability ­ Within a given timeframe ­ At a particular location ­ For a type of capability: committed, available, unattaignable · Caution : ­ The process segment capability overlaps the resource capability and those of other process segments ­ Risk of double use of the same resource 31 Production Capacity (cont'd) Current Production Capacity Unattainable Capacity Production Capacity Capacity Available Capacity Committed Capacity Current Capacity Time 32 Operations Capability Model Operations Capability 0..n Process segment Capability 0..n Equipment Capability Must correspond to element in 0..n Personnel Capability Must correspond to element in 0..n Material Capability Must correspond to element in Equipment Model Personnel Model Material Model 33 B2MML: Operations Capability - Header < OperationsCapability> Plant capability SuperToner / Site 2012-12-08 Committed On request Site 2012-12-08 2002-12-24 34 B2MML: Production capability - Personnel Molder (default) (default) < HierarchyScope > (default) (default) 2012-12-08 2012-12-18 5 MolderQualif 1 2 2+1 ??? 5 MolderQualif 2 1 35 B2MML: Process segments capability Body molding SA1 < HierarchyScope > 2012-12-08 2012-12-18 Molder 1 MolderQualif 1 1 ... ... 36 Agenda · Example ­ ­ ­ ­ Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance · · · · Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML 37 Operations schedule · The operations schedule relies on Operations and resources definitions Operations schedule Operations Request Operations Request Operations Request Operations Request Segment Segment Requirement Requirement Segment Requirement Segment Requirement Resources 38 Operations schedule ­ Corporate level Operations schedule CARTRIDGES 2012-13-08 10 cartridges 50 cartridges TN6600 HX2200 ... ... Segment Segment Requirement Requirement Enclosures Ink Segment Requirement Electronics Segment Requirement Assembly Resources = Plants, production lines 39 Operations schedule ­ Plant level Operations schedule SuperToner PLANT 10 enclosures HX2200 50 enclosures TN6600 ... ... Segment Requirement Sa1 Body Molding Segment Requirement Sa2 Cover Molding Segment Requirement Sa3 Finishing Pre-assembly. Resources: Personnel, Equipment, Material 40 Operations schedule Operations Schedule Operations Definition Corresponds to Operations Request 1..n Process or Operations Segment Corresponds to Segment Requirement 0..n Requested Segment Response 0..n 0..n 0..n 0..n Segment Equipment Personnel Material Parameter Requirement Requirement Requirement 41 B2MML : Operations schedule P020726 Updated schedule / urgent order SuperToner / Site 2012-12-08 2012-12-08 2012-12-08 OF212 Sa1 Body molding 1 H Molder Single mold. Mach. Polyethylen P22 MoldReference M6600 42 Agenda · Example ­ ­ ­ ­ Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance · · · · Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML 43 Operations performance ­ Corporate level Operations performance (production) CARTRIDGES 2012-12-08 2 cartridges HX2200 4 cartridges TN6600 ... ... Segment actual Enclosure Segment actual Ink Segment actual Electronics Segment actual Assembly Resources 44 Operations performance ­ Plant level Operations performance (production) SuperToner PLANT 8 enclosures HX2200 7 enclosures TN6600 ... ... Segment actual Sa1 Body molding Segment actual Sa2 Cover molding Resources Segment actual Sa3 Finishing ­ Pre-Assembly 45 Operations performance Operations Performance Operations Response 0..n 0..n Reports on Operations Request Segment Response Corresponds to Process Segment 0..n 0..n 0..n 0..n Segment Data Equipment Actual Personnel Actual Material Actual 46 B2MML : Production performance R020726 Daily production report SuperToner / Site 2012-12-08 P020726 2012-12-08 T00:00:00Z 2012-12-08 T24:60:60Z OF212 Molder Alfred 30min 47 Agenda · · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML 48 Peer-to-peer vs Information service bus Connect Connect Connect Connect Connect Connect Appli A Appli G Appli A Appli G Appli B Appli H Appli B . . MES / . B2M standardized messages Connect . Appli H Appli C Appli I Appli C Connect Appli I Appli D Appli J Appli D Connect Connect Appli J Appli E Appli K Appli E Appli K . 49 Exemple 50 Case 1 : ERP and MES not ISA-95 aware Send ERP message Receive ERP message Transform to B2MML message Send B2MML message Receive B2MML message Transform to MES message Send MES Message Receive MES Message ERP Mess. B2MML Mess. ERP B2MML connector MES B2MML Connector MES Mess. ERP MES 51 Case 2 : ERP is ISA-95 aware Send B2MMLmessage Receive B2MML message Transform to MES message Send MES Message Receive MES Message B2MML Mess. MES Mess. MES B2MML Connector ERP MES 52 Case 3 : ERP and MES not ISA-95 aware Send ERP message Receive ERP message Transform to B2MML message Send B2MML message Receive B2MML Message ERP Mess. B2MML Mess. ERP B2MML connector ERP MES 53 Case 4 : ERP and MES not ISA-95 aware Send ERP message Receive ERP message Transform to B2MML message Send B2MML message Receive B2MML message Transform to MES message Send MES Message Receive MES Message ERP Mess. B2MML Mess. ERP B2MML connector MES B2MML Connector MES Mess. ERP MES 54 Case 4 : ERP and MES speak B2MML Send B2MML message Receive B2MML message Warning! Custom Extensions Supported Transactions B2MML Mess. ERP MES 55 Case 4 : B2MML mapping Receive B2MML message Extension mapping Send B2MMLMessage Receive B2MML message Send B2MML message B2MML Mess. B2MML Mess. B2MML Router/mapper ERP MES 56 not c udo P i r sr ed o r r ed o not c udo P r i r su a s t t r ed o not c udo P r i r sr e m r ap t a not c udo P i r es nops e R ProductionPerformance l ar e a M i t de mm s no C u SAP WM ProductionSchedule SAP PP-PI Example not c udo P i r s u a s r ed o t t r Any/Unknown MES / control systems l ar e a M i t dec udo P r Central ERP api ERP connector Distributued MES api 57 Enterprise bus ISA-95 messages MES connectors Methodology overview Requirements 1 Business Glossary ISA-95 models 3 Business process 2 IT Applications Design 4 Transactions & message identification 5 Message definitions (xsd) Operations Message Instances (xml) 58 1. Business Glossary · Many « languages » ­ Each software solution has its own: « Batch » in ERP is « Lot » in MES, is SKU in warehouse system ­ People may use a terminology based on ­ ­ ­ ­ ­ A well established company wide glossary the current software solution An ancien sotware solution An ancien plant owner ... · ISA-95 brings an addiitonal one! ­ Can be an advantage: neutral language beyond possible political and personnal conflicts ­ Can be problematic is the company has established its own terminology 59 1. Business Glossary: an opprotunity · Designing interface is the right time to establish a common understanding on company's meta-data · ISA-95 is a semi-canonical standard ­ Imposes a given terminology for a limited set of terms ­ Standard structures and attributes: Production Request, Material Definition... ­ All other data have are custom extensions through properties or extension attributes · The « Glossary » shall be built / maintained ­ Defining an appropriate definition ­ Matching the different terms with ISA-95 standard and extensions ­ can be part of a semantic meta data registration process in the concept of a company-wide MDM effort 60 1. Business glossary example Business Term Description Range - Codes BatchManagedIndicator Allow the theoretical use of Yes/No the component in quantity ContainerWeight Define the theoretical weight value of a container HasPotency Titrisation Yes/No IsWeighed WeighingMode The material has to be Yes/No weighed List of authorized weighing 1. Net weighing methods 2. Double weighing 3. Forced input 4. Keyboard gross weighing 5. Lure gross weighing 6. Manual input 7. Authorization to mix different components 8. Counting weighing (capsule) 9. Pallet weighing 10.Laser weighing 61 2. IT applications ID MES ERP OPZ Solution FLEXNET SAP Formula+ Description Inventory management Production management Formula optimizer 62 3. Business Processes · Describe Business process workflows ­ Identify use cases involving inter-system communications ­ Describe workflows, identifies communication instances · BP example: Process Order Optimization ­ Use case: ­ optimize the formula before executing a production order, taking into account the characteristics of raw material to be used ­ Simplified : ­ We only consider the part where interoperability is involved 63 3. Business process ERP Create / Release Production Requests Manage Material MES OPZ Execute Production Requests Optimize Production Requests 64 4. Transactions & message identification · For each communication link, identify transactions · For each transaction, ­ Decide for a transaction model (Push, Pull, Publish) ­ identify the involved messages · For each message ­ ­ ­ ­ ­ Give et business relevant name and unique ID IT application origin and destination ISA-05 applicable model ISA-95 part 5 verb (action to perform) ISA-95 par 2/4 noun (the conveyed information) 65 4. Transactions & message identification ERP Create / Release Production Requests Manage Material MES s et r epo pl ar e a M i r i t OPZ T6 T3 T2 qe R not c udo P denna P i r l e R not c udo P de uc ex E i r t R not c udo P dez m p O i r i it T1 T5 Optimized Production Requests Material Properties Execute Production Requests Optimize Production Requests T4 66 T1: Planned Production Requests ERP-> MES ERP PUSH MES M1.1: Send Planned Production Requests PROCESS Operations Schedule Note: no confirmation / acknowledgement at the application level 67 T2: Executed Production Requests MES -> ERP MES PUSH M2.1 Send Production Responses PROCESS Operations Performance ERP Note: no confirmation / acknowledgement at the application level 68 T3: Material properties ERP to MES MES PULL M3.1 Query Material Properties GET Material Lot ERP M3.2 Send Material Properties SHOW Material Lot 69 T4: Material properties MES -> Optimizer MES PUBLISH M4.1 Send Material Properties SYNC Material Lot OPZ 70 T5: Optimized Production Requests MES <-> Optimizer MES PUSH M5.1 Send Planned Production Requests PROCESS Operations Schedule OPZ M5.2 Send Optimized Production Requests ACKNOWLEDGE Operations Schedule 71 T6: Optimized Production Requests MES -> ERP MES PUSH ERP M6.1 Send Optimized Production Requests PROCESS Operations Schedule 72 Message summary # Transaction Mode T1 Planned PUSH Production Requests T2 Executed PUSH Production Requests T3 Material PULL Properties (MES) T4 Material Properties (OPZ) T5 Optimized Production Requests PUBLISH M.4.1 PUSH M.5.1 Send Material Properties Send Planned Production Requests Send Optimized Production Requests Send Optimized Production Requests Mateiral Operations Schedule SYNC Material Lot MES Operations Schedule OPZ Mess. Message ISA-95 ID name Modčle Send Planned Production Operations M1.1 Requests Schedule Send Production Operations M2.1 Responses Performance Query Material M3.1 Properties Material Send Material M.3.2 Properties Material Verb Noun Operations Schedule Origin Dest. PROCESS ERP MES PROCESS GET SHOW Operations Performance MES Material lot Material Lot MES ERP ERP ERP MES PROCESS MES OPZ M.5.2 T6 Optimized Production Requests PUSH Operations Schedule Operations Acknowledge Schedule OPZ MES M.6.1 Operations Schedule PROCESS Operations Schedule MES ERP 73 5. Message definition · Messages data mapping ­ Business data correspond to ISA-95 data ­ ­ Existing attributes in the model tree structure Custom attributes extending the appropriate objetcts Feuille Microsoft Office Excel 97-2003 ­ AND applications data As a consequence, a message row relates ­ ISA-95 concept (ex : SegmentRequirement.ID) ­ Business data (ex : Process Order) ­ SAP data (ex : Y_MES_H PPPI_CONTROL_RECIPE ) ­ MES data (ex : PO_ID) · Each message mapping is an independent sub-project ­ Interface projects can be split at will : per business process, per system.. Note : The presented example is not included in the conference material (customer information) 74 Agenda · · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML 75 5. Categories of information / part 2 Enterprise Information Plant Production Scheduling, Operational Management, etc Definition Capability Information Information (What it takes to make a job) (What resources are available) Schedule Performance (What to make and use) (What was made and used) Manufacturing Control Information Area Supervision, Production, Scheduling, Reliability, Assurance, etc 76 5. Categories of information / part 4 Definition Capability Information Information (What it takes to make a job) (What resources are available) Schedule Performance (What to make and use) (What was made and used) Manufacturing Control Information 77 Extended interoperability domains Represented in the Operations Schedule model Represented in the Operations Performance model Production schedule Maintenance request Quality Test request Inventory request Production Maintenance performance response Quality Test response Inventory response Manufacturing operations management Production operations management Maintenance operations management Quality operations management Inventory operations management Product definition Maintenance definition Quality Test definition Inventory definition Production capability Maintenance capability Quality Test capability Inventory capability Represented in the Operations Definition model Represented in the Operations Capability model 78 ISA-95 part 2/4 models Category Resource ISA-95.02 Personnel Role based equipment, Physical asset, physical model, Material Resource relationship network Poential Knowledge Process segment Operations definition Operations / Kinetic knowledge Operations schedule Operations performance Operations capability Work Alert Work definition Work schedule Work performance Work capability ISA-95.04 79 Personnel (part 2) · Includes ­ persons and personnel classes (categories) ­ properties as Skills and capabilities of individuals (persons) and groups (classes) ­ Qualification Tests associated to properties ­ Results associated to property, individual and test 80 Personnel (part 2) Personnel Class Has properties of > 0..n 0..n Is tested by a > 0..n 0..n < Defined by 0..n Is tested by a > 0..n Has values for > Person Qualification Test Specification 0..n Is tested by a > 0..n Defines a procedure for obtaining a > 0..n < Maps to 0..n < Records the execution of 0..n Qualification Test Result 0..n Personnel Class Property Person Property 0..n < may contain nested 0..n < may contain nested 81 Equipment (part 2) · Split in 2 view points ­ Role based equipment (that participates in a segment activity as a functional entity) ­ Physical Asset (that identifies a given specific equipment regardless its current function / status) · Includes ­ equipment and equipment classes (type of equipment) ­ properties as characteristics / capabilities of equipment / equipment classes ­ Capability Tests associated to properties ­ Results associated to property, equipment and test 82 Role based equipment (part 2) < May be made up of 0..n Equipment Class Has properties of > 0..n 0..n 0..n Is tested by an > 0..n < Defined by 0..n Is tested by an > 0..n Equipment Has values for > Equipment Capability Test Specification 0..n Is tested by an > Defines a procedure for obtaining an > 0..n Maps to 0..n 0..n < Records the execution of Equipment Capability Test Result Equipment Class Property 0..n 0..n Equipment Property 0..n < may contain nested 0..n < may contain nested 83 Physical asset (part 2) > May be made up of 0..n > is an instance of Physical Asset Has values for > 1..1 0..n Is tested by an > 0..n 0..n 0..n Is tested by an > 0..n Physical Asset Class Has properties of > Physical Asset Capability Test Result < records the testing of Defines a procedure for obtaining an < 0..n Physical Asset Capability Test Specification 0..n 0..n Is tested by an < Maps to 0..n 0..n 0..n Physical Asset Property 0..n < may contain nested Physical Asset Class Property 0..n < may contain nested 84 Role based equipment / physical asset relationship (part 2) < May be made up of 0..n > May be made up of 0..n > Implemented by Equipment Class Has properties of > 0..n 0..n < Defined by Equipment 0..1 0..1 < records use and removal of asset to implement equipment Physical Asset > is an instance of 0..n 1..1 Physical Asset Class Has properties of > Equipment Asset Mapping 0..n 0..n 0..n 0..n Maps to Equipment Class Property Maps to Equipment Property Physical Asset Property 0..n < may contain nested Physical Asset Class Property 0..n < may contain nested 0..n < may contain nested 0..n < may contain nested 85 Material model (part 2) · Includes ­ material definitions (article id) and material classes (categories of material) ­ Material Lots and Sublots with location information ­ Properties as characteristics of material definitions, classes, lots, sublots ­ Material Tests associated to properties ­ Results associated to property, material lot/sublot and test 86 Material model (part 2) Is assembled from Is assembled from Is assembled from Is assembled from 0..n 0..n Defines a grouping 0..n 0..n 0..n 1..1 Defined by 0..n Made up of 0..n 0..n Material Class Has properties of 0..n Material Definition Has properties of Material Lot 0..n Material Sublot 0..n Is tested by a > Is tested by a > 0..n 0..n 0..n Is tested by a > 0..n Has values for Has values for May be made up of sublots Material Test Specification Defines a procedure for obtaining a 0..n Records the execution of Is tested by a > 0..n 0..n Is tested by a > 0..n QA Test Result 0..n 0..n Material Class Property 0..n < may contain nested May map to Material Definition Property 0..n < may contain nested 0..n Maps to 0..n Material Lot Property 0..n 0..n < may contain nested 87 Process segment (part 2) · A process segment: ­ the process view for the business system to control material, labor, resource usage, cost, and quality in order to control the production ­ can be more or less detailed and self contained providing a "telescopic" view of manufacturing capabilities of a given facility Also called: ­ Process stages, process operations, Unit operations, Assembly steps and assembly actions The model Defines Capability, Parameters & Resources used by the Segment (Personnel, Equipment & Materials) The Segment pattern appears in all subsequent models · · · 88 Process segment (part 2) · Business view of production Pharmaceutical Manufacturing (3 Segments) Make Active Ingredient Make Pills Package Doses Raw Materials Finished Products Inventory tracked for Active Ingredient Know throughput, resources and time to make Active Ingredient Inventory tracked for Pills Inventory tracked for Pill Packs Know throughput, resources and time to make Pills Know throughput, resources and time to make Pill Packs 89 Process segment (part 2) 0..n has an execution dependency on Process Segment is a collection of 0..n 0..n May be made up of Process Segment Dependency 0..n 0..n 0..n 0..n 0..n Process Segment Parameter 0..n May be made up of Personnel Segment Specification Has properties of 0..n Equipment Segment Specification Has properties of 0..n Physical Asset Segment Specification Has properties of 0..n Material Segment Specification 0..n Is assembled from Has properties of 0..n Personnel Segment Specification Property 0..n Corresponds to element in 1..1 Equipment Segment Specification Property 0..n Corresponds to element in 1..1 Physical Asset Segment Specification Property 0..n Corresponds to element in 1..1 Material Segment Specification Property 0..n Corresponds to element in 1..1 Personnel Model Equipment Model Physical Asset Model Material Model 90 Resource relationship network (part 4) Resource Relationship Netw ork class Resource Relationship Netw ork 1..* Resource Netw ork Connection «deri ve» Resource Netw ork Connection Type 1 To Resource Reference 1 From Resource Reference 0..* Resource Netw ork Connection Property 0..* Resource Netw ork Connection Type Property «deri ve» 0..* To Resource Reference Property 0..* From Resource Reference Property +Corresponds to el ements in +Corresponds to el ements i n Resource Models notes Any of the Personnel , Equi ment, Materi al , Physi cal Asset, Work Process Segment, or Process Segment model s 91 Capability · Uniquely define the production capability for a specific element of the equipment model ­ Given for specific resources as well as segments Provide a description of - or other information about the production capability Provide current state of the capability (available, committed, or unattainable) Define a location for the capability Define the physical level of the capability (Enterprise, Site, Area, Process Cell...) Define a Start Time and End Time that defines the lifecycle time for the capability Document the publish date for when the capability was published or generated · · · · · · 92 Operations capability (part 2) Operations Capability 1 Is a collection of 0..n 0..n 0..n 0..n 0..n Process Segment Capability Personnel Capability Has properties of 1 0..n Equipment Capability Has properties of 1 0..n Physical Asset Capability Has properties of 1 0..n Material Capability 0..n Is assembled from Has properties of 1 0..n Personnel Capability Property 0..n Corresponds to element in 1..1 Equipment Capability Property 0..n Corresponds to element in 1..1 Physical Asset Capability Property 0..n Corresponds to element in 1..1 Material Capability Property 0..n Corresponds to element in 1..1 Personnel Model Equipment Model Physical Asset Model Material Model 93 Process segment capability (part 2) Process Segment Capability Corresponds to Process Segment Is a collection of 0..n 0..n 0..n 0..n Personnel Capability Has properties of 0..n Equipment Capability Has properties of 0..n Physical Asset Capability Has properties of 0..n Material Capability Has properties of 0..n 0..n Is assembled from Personnel Capability Property 0..n Corresponds to element in 1..1 Equipment Capability Property 0..n Corresponds to element in 1..1 Physical Asset Capability Property 0..n Corresponds to element in 1..1 Material Capability Property 0..n Corresponds to element in 1..1 Personnel Model Equipment Model Physical Asset Model Material Model 94 Work capability (part 4) class Work Capability Model Work Capability 0..* Word Master Capability 0..* Personnel Capability 0..* Equipment Capability 0..* Physical Asset Capability 0..* Material Capability +Is assembled from 0..* 0..* Personnel Capability Property 0..* Equipment Capability Property 0..* Physical Asset Capability Property 0..* Material Capability Property +Corresponds to element in 0..* 1 +Corresponds to element in 0..* 1 +Corresponds 0..* to element in 1 Physical Asset Model +Corresponds to element in 0..* 1 Personnel Model Equipment Model Material Model 95 Work Master capability (part 4) class Work Master Capability Model Work Master Capability Work Master +Corresponds to 0..* 1 0..* Personnel Capability 0..* Equipment Capability 0..* Physical Asset Capability 0..* Material Capability +Is assembled from 0..* 0..* Personnel Capability Property 0..* Equipment Capability Property 0..* Physical Asset Capability Property 0..* Material Capability Property +Corresponds to element i n 0..* 1 +Corresponds to element in 0..* 1 +Corresponds to element in 0..* 1 +Corresponds to element in 0..* 1 Personnel Model Equipment Model Physical Asset Model Material Model 96 Definition · A definition specifies the resources required to perform a specified operation such as making a product, maintaining an equipment, teaching an operator, executing a quality analysis or moving materials. ­ Defines a sequence of "Operations segments" · It does not describes how to perform this work in detail, though this information can be handled as ­ general, site or master recipe (IEC 61512-1 and ANSI/ISAS88.01-1995 definition), ­ standard operating procedure (SOP), ­ standard operating conditions (SOC), And attached to the Operations definition and its segments 97 Operations definition (part 2) Has a reference to < Has a reference to > Bill of Resources (External) Has associated > May be made up of 0..n has an execution dependency on 0..n 0..n Operations Definition Has associated 0..n 1..n 1..1 Work Definition (External) Bill of Material (External) may have a reference to > Has associated > 0..n May have a reference to > Corresponds to 0..n 1..n Operations Material Bill 0..n Operations Segment Process Segment Operations Segment Dependency 0..n 0..n Is a collection of 1..1 0..n Operations Material Bill Item 0..n Is assembled from 0..n 0..n 0..n 1..n Parameter Specification 0..n May be made up of Personnel Specification Equipment Specification Physical Asset Specification Material Specification 0..n Is assembled from 0..n 0..n 0..n 0..n Personnel Specification Property 0..n Corresponds to element in Equipment Specification Property 0..n Corresponds to element in Physical Asset Specification Property 0..n Corresponds to element in Material Specification Property 0..n Corresponds to element in 1..1 1..1 1..1 1..1 Personnel Model Equipment Model Physical Asset Model Material Model 98 Work definition (part 4) class Work Definition Model Operations Definition +May have reference to Work Definition Abstract Type Work Master 1 +is created from 0..* Work Directiv e 0..* 0..* +May be made up of 0..* 0..* Parameter Specification 0..* Personnel Specification 0..* Equipment Specification 0..* Physical Asset Specification 0..* Material Specification +Is assembled from 0..* 0..* Workflow Specification 0..* Personnel Specification Property 0..* Equipment Specification Property 0..* Physical Asset Property 0..* Material Specification Property +Corresponds to element in 0..* +Corresponds to element in 0..* +Corresponds to element in 0..* +Corresponds to element in 0..* 1 Personnel Model 1 Equipment Model 1 Physical Asset Model 1 Material Model 99 Schedule · What to make and what to use · Operations schedule information ­ Is a collection of Operations Requests · Operations request ­ information required to fulfill the scheduled operation. ­ a collection of Segment Requirements ­ May reference the associated operations instructions · A segment Requirement ­ Shall correspond to an existing operations or process segment ­ Defines specific Equipment, Personnel, Material requirements and Operations parameters ­ There may only be one production segment, ­ But at least one! 100 Operations schedule (part 2) Operations Definition Operations Schedule Is made up of 1..n May correspond to an < Operations Request Is made up of May correspond to an < 1..n 0..n Process Segment Corresponds to an < Segment Requirement 0..n May contain 0..n Requested Segment Response May contain 0..n 0..n 0..n 0..n Segment Parameter 0..n May be made up of Corresponds to a Personnel Requirement Equipment Requirement Physical Asset Requirement Material Requirement 0..n Is assem bled from 1..n 1..n 1..n 1..n Personnel Requirement Property Corresponds to element in the Equipment Requirement Property Physical Asset Requirement Property Material Requirement Property Corresponds to element in the Corresponds to element in the Corresponds to element in the Parameter Specification or Process Segment Parameter Personnel Model Equipment Model Physical Asset Model Material Model 101 Work Schedule (part 4) Work Schedule Job List Work Request +Made be made up of 0..* 1..* Work Master +Corresponds to Job Order 1..* +May be made up of 0..* +May be made up of 0..* 0..* Job Order Parameter 0..* Personnel Requirement 0..* Equipment Requirement 0..* Physical Asset Requirement 0..* Material Requirement +Is assembled from 0..* 0..* Personnel Requirement Property 0..* Equipment Requirement Property 0..* Physical Asset Requirement Property 0..* Material Requirement Property +Corresponds to element in 1 Personnel Model +Corresponds to element in 1 Equipment Model +Corresponds to element in 1 Physical Asset Model +Corresponds to element in 1 Material Model 102 Performance What was made and what was used - example · A Operations Performance ­ Is a collection of Operations Responses · A Operations Response ­ Is a collection of Segment Response ­ Corresponds to a specific Production Request · A segment Response ­ Correspond to a specific segment requirement ­ Reports What resources were actually used, consumed, produced and other production data 103 Operations performance (part 2) Operations Definition Operations Performance Is made up of 1..n May correspond to a > 0..n 0..1 May correspond to an < Operations Response Operations Request Is made up of May correspond to an < 1..n Process Segment Corresponds to a < Segment Response 0..n May contain May contain 0..n 0..n 0..n 0..n 0..n Segment Data 0..n May be made up of Personnel Actual Equipment Actual Physical Asset Actual Material Actual 0..n Is assembled from 1..n 1..n 1..n 1..n Personnel Actual Property Corresponds to element in Equipment Actual Property Physical Asset Actual Property Corresponds to element in Material Actual Property Corresponds to element in Corresponds to element in Personnel Model Equipment Model Physical Asset Model Material Model 104 Work performance (part 4) Work Performance +May be m ade up of 0..* Work Response +May be made up of 0..* +Is made up of 1..* Job Response Work Directiv e +Corrsponds to 0..1 +May be made up of 0..* 0..* +May be made up Job Response Data of 0..* 0..* Personnel Actual 0..* Equipment Actual 0..* Physical Asset Actual 0..* Material Actual +Is assem bl ed from 0..* 0..* Personnel Actual Property 0..* Equipment Actual Property 0..* Physical Asset Actual Property 0..* Material Actual Property +Corresponds to el ement in 0..* +Correspondes to el ement in 0..* +Correspondes to element i n 0..* +Correspondes to element i n 0..* 1 Personnel Model 1 Equipment Model 1 Physical Asset Model 1 Material Model 105 Segments, Segments, Segments... · Process segment: manufacturing capability ­ Defines the manufacturing process available per segment ­ Gather the required resources to execute the defined operations segments · Operations/Work Segment: manufacturing requirements ­ Defines the specifications per operations segment ­ Details the required resources for this operations segment · Segment Requirement: run time requirements ­ Defines the specifics for an operations request · Segment Response ­ Reports the actual happening 106 Segments, Segments, Segments... Operaitons / Work capability Operations / Work definition Operations segment ·Parameter ·Resource specification Operations / Work schedule Segment requirement ·Parameter ·Resource requirement Operations / Work performance Segment response ·Parameter ·Resource actual Process segment ·Parameter ·Resource specification 107 s n o i t a r e p O s n o i t a r e p O i t a m r o f n I l u s r d n e k m o t a h W Summary / part 2 e lb v is t a h W m r o f n I y t l i b p a C e c r u o s R t l i y b a C p h W c u o s e r t a ilb v e r a t O o i a p s n r e t n m g e S y t l i b p a C o d e b n c t a h W u o s r e h it w c s e c o r P s t n m g e S s io c n u f t a h W ilb v e r a o s t n io t a r e p m f s n o i t a r e p O o t n i f e D t w o H an in t a r e p o m o f r e p s n o i t a r e p O l u d e h c S e b o is t a h W m s u & e d a s n t a r e io p O l u d e h c S s n o i t a r e p O c n a m o f r e P s w t a h W s u & e d a m s n io t a r e p O c n a m o f r e P May correspond to a s n io t a r e p O y ilt b p a C s n io t a r e p O o t in f e D s n t a r e io p O t s u q e R s n io t a r e p O n o p s e R May correspond to a Must correspond to a Must correspond to a May correspond May correspond to a to a s n io t a r e p O t n m g e S y ilt b p a C s e c o r P t n m g e S s n io t a r e p O t n m g e S t n m g e S t n m ir u q e R t n m g e S n o p s e R May correspond to a May correspond to a May correspond to a c r u o s e R y ilt b p a C c r u o s e R y ilt b p a C c r u o s e R S n o t a if c e p c r u o s e R S n o t a if c e p c r u o s e R m ir u q e t n R c r u o s e R l a u t c A May correspond to a May correspond to a May correspond to a May correspond to a c r u o s e R y ilt b p a C P r y t e p o c r u o s e R y ilt b p a C y t e p o r P c r u o s e R S n o t a if c e p y t e p o r P c r u o s e R n o t a if c e p S y t e p o r P c r u o s e R t n m ir u q e R y t e p o r P c r u o s e R l a u t c A y t e p o r P 108 m r o f n I y t l i b p a C Summary / part 4 e ilb v a s t h W k r o W c r u o s e R y t l i b p a C c u o s e r t a h W ilb v e r a k r o W e t s a M r a C i b p t l y o d e b n c t a h W c u o s r e h it w y ilt b p a C k r o W m f r e p t w o H r k o W e t s a M r k r o w e b o is t a h W d m o f r e P im t y b c u o s r & e b o J t s i L k r o W l u d e h c S e b o is t a h W d m o f r e P c n a m o f r e P k r o W s w t a h W d m o f r e p v t c e r i D m f r e p t w o H b jo if c e p s a k r o W l u d e h c S k r o W d n p s e r o C a o t c n a m o f r e P k r o W t is L b o J t s u q e R k r o W d n p s e r o C a o t n p s e R k r o W k r o W r e t s a M b p a C y ilt d n p s e r o C a o t k r o W r e t s a M d n p s e r o C a o t e d r O b o J d n p s e r o C n p s e R b o J a o t d n p s e r o C a o t k r o W v t c e ir D o r u s c e R a C y ilt b p d n p s e r o C a o t c r u o s e R t n m g e S y ilt b p a C d n p s e r o C a o t o e R c r u s n o t a if c e p S d n p s e r o C a o t c r u o s e R t n m ir u q e R d n p s e r o C a o t c r u o s e R l a u t c A d n p s e r o C a o t c r u o s e R n o t a if c e p S o e R r u s c y ilt b a p C e p r P y t o d n p s e r o C a o t c r u o s e R t n m g e S y ilt b p a C y t e p o r P d n p s e r o C a o t c r u o s e R R o e c r u s n o t a if c e p S P r o y e p t d n p s e r o C a o t c r u o s e R t n m ir u q e R y t e p o r P d n p s e r o C a o t c r u o s e R l a u t c A y t e p o r P d n p s e r o C a o t c r u o s e R n o t a if c e p S y t e p o r P P M A a c y h t m ip u q E l, n o s r e 109 AGENDA · · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML 110 ISA95 part 5 · The Open Application Group ­ OAG ­ publishes an extensive XML schema specification for exhanging information to/from/between business systems (ERP) ­ www.openapplications.org ­ It sometimes overlaps with ISA95 · Currently (04/2008) version 9.2, includes some ISA95 models · OAGIS defines messages based on a VERB-NOUN combination to properly handle complete transactions ­ Allowing Push/Pull/Publish-Subscribe transactional modes · The ISA95 part 5 standard extend part 1/2 to specify applicable transactions/messages ­ It only use a subset of the OAGIS VBERBS 111 Messages et transactions Message : · a structured Owner of information information unit conveyed in a oneLocal way transfer of data processing from one sending application to one or more receiving applications Transaction : SHOW · a sequence of related messages that are exchanged among applications GET Equipment Application Identification Area Data Area VERB = GET Noun = Equipment ID= "ABC" User of information GET SHOW Equipment Application Identification Area Data Area VERB = SHOW Noun = Equipment ID= "ABC" Description = "Simple equipment" Equipment Property ID = "Throughput" Value = 200 PPM Description = "Throughput as parts per minute" ... 112 Message Structure · Content of a message: ­ Application identification area ­ typically includes the electronic address of the sender, an indication of the confirmation requirement, and the date and time the message was created ... Message Application Identification Area Data Area VERB NOUN ­ Data Area ­ VERB ­ defines the action to be performed, or the response to a request ­ Data Area ­ NOUN ­ represents one or more objects, as defined in the Part 1 and Part 2 object models · The above information defines a unique and unambiguous meaning of messages 113 Verb list Verb ACKNOWLEDGE CANCEL CHANGE CONFIRM Description Acknowledgement of a PROCESS request. Request to a receiver to remove information. Request to a receiver to change information. Confirmation response to a request. Model PUSH PUSH PUSH PUSH, PULL PUBLISH PULL PUSH PUSH PULL PUBLISH PUBLISH PUBLISH GET PROCESS RESPOND SHOW SYNC ADD SYNC CHANGE SYNC DELETE Request to a receiver for information on one or more objects. Request to a receiver to process new information. Response to a CHANGE message request. Response to a GET message. Request from the owner of the object to add information Request from the owner of the object to change information Request from the owner of the object to delete information Noun list Personnel Class Person Qualification Test Specification Equipment Class Equipment Equipment Capability Test Specification Physical Asset Class Physical Asset Physical Asset Capability Test Specification Material Class Material Definition Material Lot Material Sublot Material Test Specification Resource Relationship Network Connection Type Resource Relationship Network Connection Process Segment Operations Capability Work Capability Operations Definition Work Directive Work Master Workflow specification Operations Schedule Work Schedule Job list Operations Performance Work Performance Work Alert Transaction Service Profile Agenda · · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML 116 Overview · The ISA95 object models may be used as the basis for formalized information exchange protocols ­ Such as SQL tables, XML internet files, or IDL object definitions · B2MML is originally an XML implementation of ISA95 ­ Along with BatchML for ISA88 · B2MML = ISA88+ISA95 data structures implementation ­ BatchML (ISA88 part 2) and new ISA88 models (Part 3 and 4) are now merged into B2MML · B2MML is developed by the WBF ­ WBF is an ISA sponsored/supported organization ­ B2MML is for "Business To Manufacturing Markup Language" ­ Has become the de facto implementation standard for business to manufacturing information exchange · B2MML benefit of a reactive development environment ­ About 1 version / year 117 Example: Personnel schema Information About Personnel Classes Information About Tests Information About Persons Personnel Class Has properties of > 0..n 0..n Is tested by a > 0..n 0..n < Defined by 0..n Is tested by a > 0..n Person Has values for > Qualification Test Specification 0..n Is tested by a > 0..n Defines a procedure for obtaining a > 0..n < Maps to 0..n < Records the execution of 0..n Qualification Test Result 0..n Personnel Class Property Person Property 118 Example: Personnel schema - Header 119 Extension mechanism 120 Example: Personnel schema ­ root element 121 Download the latests · This presentation (and many others) ­ http://www.syntropicfactory.com/node/3798 · B2MML ­ http://wbforg.affiniscape.com/displaycommon.cfm?an=1&subarticlenbr= ­ https://services.mesa.org/ResourceLibrary/ViewCategory/8c65bee5-db · ISA95 committee ­ http://www.isa.org/isa95 122 Thank You j.vieille@controlchaingroup.com www.syntropicfactory.com www.controlchaingroup.net 123