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