This work is licensed under a Creative Commons Attribution-ShareAlike 3.0 Unported License. Attribution: Jean Vieille Work: ISA8895 Implementation Section: Overview Chapter: Modelling Language: English Version: V3 - 05/2011 Jean Vieille www.syntropicfactory.info j.vieille@syntropicfactory.info Research community www.controlchainmanagement.org Consulting group www.controlchaingroup.com Agenda ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology 1_12_ISA8895_Overview_Introduction_Modeling 2 Automation challenge Ideal Automation Flexibility ISA-88 « manual Control » Capability Darin Flemming Lou Pillai « Classical » Automation Complexity 3 1_12_ISA8895_Overview_Introduction_Modeling ISA88 standard US and International "Batch Control" standard The ISA88 committee develops the US ANSI standard The IEC65A WG11 develops the IEC international standard US standard ANSI/ISA-88.00.01: 2010 ANSI/ISA-88.00.02: 2001 ANSI/ISA-88.00.03: 2003 ANSI/ISA-88.00.04: 2006 ISA Draft88.00.05 INTL Standard IEC 61512-1: 1997 IEC 61512-2: 2001 IEC 61512-3: 2008 IEC 61512-4: 2009 Sub Title Part 1: Models and Terminology" Part 2: Data structures and guidelines for languages Part 3: General and Site Recipe - Models and Representation Part 4: Batch Production Records Part 5: Implementation Models & Terminology for Modular Equipment Control 1_12_ISA8895_Overview_Introduction_Modeling 4 ISA88 snapshot Object Design of automation applications Ø Reuse, Knowledge Management, Robustness Flexible Design of automation applications - No programming required for Ø Modification of recipes, making different products with the same facility Ø Using alternate equipment for the same production step Ø Sequencing production runs for different products Interoperability Ø Assembling software components from different origins Product Industrialization Ø Neutral specification of product physico-chemical transformations Ø Conversion of this specification into operating procedure for target facilities Production Information Ø Data structures for production information history Ø Includes several ISA-95 models Applications Ø Initially designed for Batch processes, but applicable to any type of process Ø Functional specification, batch managers, historians, PDM/PLM 1_12_ISA8895_Overview_Introduction_Modeling 5 ISA88 Adoption Automation Functional Engineering Good Practices Ø Largely applied worldwide, proven benefits Best known in process industries Ø Less in other domains... All automation vendors offer solutions Ø Generally limited to the support of recipes (authoring, execution, reporting) Ø Sometime at the equipment control level Applies more and more to all types of production Ø No equivalent standards for discrete and continuous processes... Ø Adapt easily Ø Most benefits with globalized application: all types of processes, all locations 1_12_ISA8895_Overview_Introduction_Modeling 6 Agenda ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology 1_12_ISA8895_Overview_Introduction_Modeling 7 ISA95 snapshot B2M: Collaboration Business / Execution Ø Communication between execution systems (MES/MOM, DCS, MMS, LIMS, WES, SCADA,...) and business systems (ERP, SCM) Ø Master data management MES/MOM : Functional definition Data and Activity models Ø Description of resources, capability, products, work order requests and reports Ø Definition of operation management activities (MES) Applications: Ø User requirements and functional specification of MES and B2M interfaces Ø Native B2M connectors - MES/ERP (B2MML) Ø Possible basis for developing MES applications and software... 1_12_ISA8895_Overview_Introduction_Modeling 8 What is ISA95? US & International standard "Enterprise - Control System Integration" The ISA95 committee develops the ISA-95 standards The ISO/IEC JWG5 develops the international standard INTL Standard IEC/ISO 62264-1: 2003 IEC/ISO 62264-2: 2004 IEC/ISO 62264-3: 2007 IEC/ISO 62264-5: 2010 (APUB) Sub Title Part 1: Models and Terminology" Part 2: Data Structures and Attributes" Part 3: Activity Models of Manufacturing Operations Management (Part 4: Object Models and Attributes of Manufacturing Operations Management) Part 5: Business to Manufacturing Transactions US standard ANSI/ISA-95.00.01: 2010 ANSI/ISA-95.00.02: 2010 ANSI/ISA-95.00.03: 2005 ISA draft 95.00.04 ASNI/ISA-95.00.05: 2007 1_12_ISA8895_Overview_Introduction_Modeling 9 Benefits and adoption of ISA95 Benefits: Ø Direct : Cost and risk reduction of MES and B2M projects Ø Indirect : § Improvement of operational performance : CTP, agile manufacturing, planning feedback, error reduction § Dynamization of IT/Business alignment Adoption: Ø Most automation / MES vendors claim their adhesion to ISA95 Ø ERP vendors ignore it § Noticeable exception: SAP since 2004 Ø B2MML becomes the de facto standard for B2M information exchange 1_12_ISA8895_Overview_Introduction_Modeling 10 Agenda ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology 1_12_ISA8895_Overview_Introduction_Modeling 11 CCM global IIPS life cycle IIPS : Industrial Information Processing Systems Manage Strategy Guidance Master Planning User Requirement s Execute IIPS Construction IIPS Support Maintenance IIPS Deployment IIPS Operation Use Industrial Architecture Information Technology 1_12_ISA8895_Overview_Introduction_Modeling 12 CCM global IIPS life cycle Information Service Definition Industrial Architecture User Requirement s IT Resource Development IIPS Construction IIPS Support Maintenance IIPS Deployment IIPS Operation Run-time Information Processing 1_12_ISA8895_Overview_Introduction_Modeling 13 ISA95 like IIPS life cycle Run-time Information Processing Information Service Requests Information Services Requests Information Services (BP) Information Services (Task) Information Services (implemented) Resources HW, SW, DWH Information Services Capability Information Service Definition IT Resource Development 14 1_12_ISA8895_Overview_Introduction_Modeling Agenda ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology 1_12_ISA8895_Overview_Introduction_Modeling 15 Industrial Architecture Models Purpose Scope Ø The entire industrial facility ­ the Production sub-system within the Enterprise system Ø Spatio-temporal description (structures and interactions) of this subsystem Ø The information reality that tights Energy and Matter together Ongoing maintenance Ø This module only presents models for describing the facility Ø However, the facility is ever changing. § The Industrial Architecture Processes (IAP) integrates IAM within the global enterprise strategy definition and fulfillment process IAM provides the framework Ø For capturing and managing knowledge Ø For mastering IIPS development planning 1_12_ISA8895_Overview_Introduction_Modeling 16 Industrial Architecture Dimensions Product Asset Management Physical Asset Management Operations Process Management Inventory Asset Management Physical Process Management Physical Process Control ISA88 Equipment Control ISA88 + ISA95 TOGAF ITIL 1_12_ISA8895_Overview_Introduction_Modeling 17 IT Asset Management ISA95 Human Asset Management IIPS Scope in Industrial Architecture framework Business Information Processing Systems Marketing, R&D, HR, Engineering, Sales, Purchasing, Finance/accounting, planning Industrial Information Processing Systems ISA95 ISA 88 Operations Process Management Resource & Definitions Management Scheduling, Dispatching, Analysis, Performance, Tracking, Reporting Production Inventory, Logistics Quality Maintenance Tooling ... Risk & Safety Information Configurations Documentation Regulation Incidents & Deviations ... Physical Process Management Work Segments & Resources Physical Process Control Operating procedures, Routings, Recipes Equipment Control Basic, Procedural, Coordination Control 1_12_ISA8895_Overview_Introduction_Modeling 18 Common IT systems involved ERP Operations Process Management Physical Process Management MES Physical Process Control AUTOMATION Equipment Control 1_12_ISA8895_Overview_Introduction_Modeling 19 Agenda ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology 1_12_ISA8895_Overview_Introduction_Modeling 20 ISA88 Process model (Processing Requirement) Process A Process is made up of an ordered set of one or more Process Stages Process Stage A Process Stage is made up of an ordered set of one or more Process Operations Process Operation A Process Operation is made up of an ordered set of one or more Process Actions Process Action 1_12_ISA8895_Overview_Introduction_Modeling Product Inventory Asset Physical Asset Human Asset Asset IT Asset 21 Resource models (Structural description) The resource asset models (Personnel, Equipment, and Material) are based on the ISA-95 breakdown. All these resources share a similar pattern. Equipment and Material are indeed the same entity: A "machine" can be: Ø A "Physical Asset" for the company that makes products with it, Ø An "Inventory Asset" for the company that makes them (finish product) or sell / distributes it 1_12_ISA8895_Overview_Introduction_Modeling Product Inventory Asset Physical Asset Human Asset Asset IT Asset 22 ISA95 Material Model 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 0..n < may contain nested 0..n < may contain nested 0..n < may contain nested 1_12_ISA8895_Overview_Introduction_Modeling Product Inventory Asset Physical Asset Human Asset Asset IT Asset Material Class Property May map to Material Definition Property 0..n Maps to 0..n Material Lot Property 0..n 23 ISA95 extended physical model (Actual Facility layout) ENTERPRISE SITE AREA WORK CENTER PROCESS CELL PRODUCTION UNIT PRODUCTION LINE STORAGE ZONE BATCH PROCESS (ISA88) CONTINUOUS PROCESS DISCRETE PROCESS WAREHOUSE WORK UNIT UNIT UNIT WORK CELL STORAGE UNIT CONTROL MODULE 1_12_ISA8895_Overview_Introduction_Modeling Product Inventory Asset Physical Asset Human Asset Asset IT Asset EQUIPMENT MODULE 24 ISA95 Equipment Model < May be made up of 0..n 0..n 0..n 0..n Is tested by an > 0..n < Defined by 0..n Is tested by an > 0..n Equipment Class Has properties of > 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 0..n < may contain nested 0..n < may contain nested 1_12_ISA8895_Overview_Introduction_Modeling Product Inventory Asset Physical Asset Human Asset Asset IT Asset Equipment Class Property 0..n 0..n Equipment Property 25 ISA95 Personnel Model Personnel Class Has properties of > 0..n 0..n Is tested by a > 0..n < Defined by 0..n Is tested by a > 0..n Has values for > Person 0..n 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 Qualification Test Result Product Inventory Asset Physical Asset Human Asset Asset IT Asset 0..n 0..n Personnel Class Property Person Property 1_12_ISA8895_Overview_Introduction_Modeling 26 ISA88 Procedural Control model (Equipment/Product Interactions) Procedure A Procedure is made up of an ordered set of one or more Unit Procedures Unit Procedure A Unit Procedure is made up of an ordered set of one or more Operations Operation An Operation is made up of an ordered set of one or more Phases Phase 1_12_ISA8895_Overview_Introduction_Modeling Product Inventory Asset Physical Asset Human Asset Asset IT Asset 27 ISA95 Segment Model 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 Has properties of 0..n 0..n Is assembled from 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 1_12_ISA8895_Overview_Introduction_Modeling Product Inventory Asset Physical Asset Human Asset Asset IT Asset 28 ISA95 Operational Activity Model 1.Detailed scheduling 8. Resource management 2. Dispatching 7. Definition management 3. Execution 4. Data collection 5. Tracking 6. Analysis Production Quality Control Inventory Maintenance 1_12_ISA8895_Overview_Introduction_Modeling Product Inventory Asset Physical Asset Human Asset Asset IT Asset Other 29 Agenda ISA88 snapshot ISA95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology 1_12_ISA8895_Overview_Introduction_Modeling 30 Production system Lifecycles Market Demand Customer Orders / Forecast Manufacturing Product R&D Engineering 1_12_ISA8895_Overview_Introduction_Modeling 31 ISA88 & ISA95 models in Production Lifecycles ISA-88 models · Operations Recipe Procedural I S A 8 8 m o d el s A ct iv it y · ISA-95 models Schedule · Performance · ISA-88 models Process · Recipe Procedural · ISA-88 models Physical · Equipment Procedural · ISA-95 models · ISA-95 models Personnel, Equipment, Material · Capability, Segment · Product Definition Product development Engineering I S 1_12_ISA8895_Overview_Introduction_Modeling 32 ISA88 & ISA95 Objects in Production Lifecycles Schedule 3. Operations Requests / Recipes Segments / RPE Product Definition 1. Product Dévelopment Segments PE/RPE Segments EPE Capability Resources Personnel / Equipment / Material 2. Engineering 1_12_ISA8895_Overview_Introduction_Modeling 33 Agenda ISA88 snapshot ISA95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology 1_12_ISA8895_Overview_Introduction_Modeling 34 IAM framework definition overview (see IAP) P&ID R&D 1b. Physical Modelling CCM Rules & Tools Use Build Improve 1a. Product Modelling 3. Process Procedural Modelling 4. Segments Modelling 5. Operation Process Modelling 1a. Inventory 1c. Human Modelling Modelling Object classes and models repository Use Build Improve 2. Equipment Control Modelling IT modelling 1_12_ISA8895_Overview_Introduction_Modeling 35 Ongoing Industrial Architecture P&ID R&D Goveranc e Enabling CCM Rules & Tools Use Build Improve 1b. Physical Modelling 2. Equipment Control Modelling IS I /95 -88 A 1a. Product Modelling 3. Process Procedural Modelling 1a. Inventory 1c. Human Modelling Modelling -9 5 ISA Persisten ce Object classes and models repository -88 SA 4. Segments Modelling -95 5. Operation SA IProcess Modelling IT modelling Use Build Improve 1_12_ISA8895_Overview_Introduction_Modeling 36 Interactions Hierarchy Business Business Processes Business Activities Exécution (ISA-95, MES) Operation Processes Operation Activities (ISA-88, Equipment Control) Operating Instructions Procedural Elements Physical Processes Recipes, routing 37 1_12_ISA8895_Overview_Introduction_Modeling Examples of Description standards Business / Operation process Description: BPMN, OSSAD, UML Schedule Requests / Recipes Segments / RPE Product Definition Segments PE/RPE Product Definition: PPC Physical Process Description : PFC Capability Segments EPE Resources Personnel / Equipment / Material 1_12_ISA8895_Overview_Introduction_Modeling 38 Modular ISA88/95 structure Entreprise, Site, Area, Work Center, Work Unit Physical Breakdown Production, Quality, Inventory, Maintenance Domains Object Classes (Templates) Functionnal Objects Decisional Level Business Processes, Operation Processes Physical Processes Equipment control Run, Stop, Hold... Exclusive States 1_12_ISA8895_Overview_Introduction_Modeling 39 Information Elements Domain Model Std Cliquez sur l'icône pour ajouter un tableauISA-88 Product Asset Process Product ISA-95 Inventory Asset Equipment Asset Material Physical Equipment Physical Asset Personnel Procedural Procedural ISA-95 ISA-88 ISA-95 ISA-95 ISA-88 ISA-88 Information elements Product Hierarchy Product Definition Material Resources Equipment Hierarchy Equipment Resources Personnel Hierarchy Personnel Resources Functional Hierarchy Equipment Procedural Elements Physical Processes / Procedural Elements Physical Process Transform Components Segments Human Asset Equipment Control Physical Process Control Physical Process Mngt Segment Operation Process Mngt Operation Activity ISA-95 ISA-95 Operation Processes Activities / Tasks 1_12_ISA8895_Overview_Introduction_Modeling 40 Thank You ! 1_12_ISA8895_Overview_Introduction_Modeling 41