This work is licensed under a Creative Commons Attribution-ShareAlike 3.0 Unported License. Attribution: Jean Vieille Work: ISA8895 Implementation Section: Function Chapter: Physical Process Management 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 Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise 3_30_ISA8895_Function_PhysicalProcessManagement 2 CC functional domains 3_30_ISA8895_Function_PhysicalProcessManagement Product Asset Management Inventory Asset Management Physical Asset Management Human Asset Management TOGAF ITIL ISA88 + ISA95 ISA88 ISA95 3 IT Asset Management Information Elements Cliquez pour ajouter Stdtableau un Domain sur l'icôneModel Information elements Product Asset Inventory Asset Physical Asset Human Asset Equipment Control Physical Process Control Physical Process Mngt Operation Process Mngt Product Product Material Physical Equipment Personnel Procedural Procedural Segment Operation Activity ISA88 ISA95 ISA95 ISA88 ISA95 ISA95 ISA88 ISA88 ISA95 ISA95 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 Operation Processes Activities / Tasks 4 3_30_ISA8895_Function_PhysicalProcessManagement Who's / What's concerned? PRM Usr/Rsp Cliquez sur l'icône pour ajouter unUsage tableau Typ.IT app Customer order processing Production planning & scheduling Production control Material and energy control Procurement Quality assurance Product inventory control Product cost accounting Product shipping administration Maintenance management Research & development Engineering X R X X X X 3_30_ISA8895_Function_PhysicalProcessManagement 5 Agenda Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise 3_30_ISA8895_Function_PhysicalProcessManagement 6 ISA95 Segments A segment describes a product related processing stage involved in Ø Specification for the product definition Ø Description of the capability of the facility Ø Requirement for executing a specific production Request In ISA-95, it currently Ø Identifies the processing stage (its identifier) Ø describes the resources involved for its execution Segment are logical views of the actual processing Ø They can be defined hierarchically. A segment can § Correspond to the product itself (possibly involving the whole plant or even several plants) § Correspond to a single ISA88 phase 3_30_ISA8895_Function_PhysicalProcessManagement 7 ISA95 Segments The picture below represents the process segment information Assembly Inspect Paint I-Beam Laborer 3x 8 hour Inspector 2x .25 Hour Mixing Cans Rollers Certified Painter = TRUE Type = Stainless Steel 3_30_ISA8895_Function_PhysicalProcessManagement 8 ISA95 Segments A logical Telescopic View of the Production System Drug XX manufacturing Raw Materials S1. Active Ingredient S2 Shaping S3 Packing Finished Products S1.1 Ingredient 1 Manufacturing S1.2 Ingredient 2 Manufacturing S1.3 Blending S1.1.1 Pre-mixing S1.1.2 Reaction S1.1.3 Filtration 9 3_30_ISA8895_Function_PhysicalProcessManagement Use of Segments for planning purpose Collection of Process Segments B C A Parameters Equipment Material Personnel Product Segments for a single product definition, with routing (e.g. Product YYY) must reference E D C E A must reference C Segment Requirements for a specific production request (e.g. Lot 123 of Product YYY E A Product Parameters Equipment Specifications Material Specifications Personnel Specifications Production Parameters Equipment Requirement Material Requirement Personnel Requirement 3_30_ISA8895_Function_PhysicalProcessManagement 10 ISA95 Process 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 Resources 3_30_ISA8895_Function_PhysicalProcessManagement 11 From ISA88 Process Model to ISA95 ProductDefinition ISA95 defines Segment as the breakdown of Operation physical activities Ø Product Segment Ø Process Segment Ø Operation/Work Segment (futur) The ISA-95 Segment model can address all stages of Product Lifecyle Ø Equipment independent processing requirement (the current topic) Ø Process operation description Ø Facilitiy's processing capabilities It can implement ISA88 Process Elements defined in Product hierarchy model and described in EIR model 3_30_ISA8895_Function_PhysicalProcessManagement 12 Operations Definition Model 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 Operations Material Bill Item 0..n 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 Resources 13 3_30_ISA8895_Function_PhysicalProcessManagement Process and Product Segments Process segment: manufacturing capability Ø Defines the manufacturing process available per segment Ø Gather the required resources to execute the defined production segments Product Segment: manufacturing requirements Ø Defines the product specifications per production segment Ø Details the required resources for this production segment § Personnel (ex:3 operators) § Equipment (ex:1 packing machine) § Materials (ex: 1500 bottles) § Parameters (ex: shape, size) May correspond to ISA88.01 definitions: (exemples) Ø Product segment --> Process stage (General/Site recipe) Ø Process Segment --> Unit Procedure (Master Recipe) 3_30_ISA8895_Function_PhysicalProcessManagement 14 Product Segment vs Process Segment Ø More information at the Product Segment level = § (-) less information at the Process segment level, § (+) more flexibility (+) More exchanged information Process Segments: · Pen Assembly · Ball · Reservoir · Point · Ink · Body Process Segments : · Make balls · ... · Product segment · CrystalBlackFineBall Product segment: · CrystalBlackFineBall · Ball · Reservoir · Point · Ink · Body · Assembling Business Manufacturing Pen Assembly 3_30_ISA8895_Function_PhysicalProcessManagement 15 Agenda Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise 3_30_ISA8895_Function_PhysicalProcessManagement 16 Enterprise global model Shareholders Bank Gover Money In nment etc Capital Benefit Money Out Emplo yees, Gover nment, Bank, etc Company Investment, Inventory & Cash Flow Profit Business Money In Customers Knowledge In Money Chain Control Design Knowledge Out Chain Energy Chain Energy R. Material Suppliers Money Out F. Product 3_30_ISA8895_Function_PhysicalProcessManagement 17 Segment as a Process The Segment concept in ISA95 is one of the most poweful feature in ISA95. Pragmatically defined as a grouping of resources, it in fact model the physical processes. As any process, they can be characterized by: Owner I/Os Metrics Best Practices Resources Workflow involving Activities, roles, resources... puts Segment Outputs Best Practices Metrics Resources 3_30_ISA8895_Function_PhysicalProcessManagement 18 Energy Chain = Segments Company Money Enterprise Money Money Chain Information Supplier Energy Chain = Segments Customer Material Energy Personnel Equipment IT Asset Money Information Money Material Energy Personnel Equipment IT Asset Money Information Trash, Scrap Losses 3_30_ISA8895_Function_PhysicalProcessManagement 19 A Segment is a Transformer Segment Resource Flow Usage Taken From More specifically, a Stored segment is a Converted "Transformer" that acts on Invested a target `flowing" resource Borrowed that increases its value Tested through the segment, Processed thanks to used resources Consumed that elevate the value to Produced Exploited the target resource at Served some cost. Recovered Sent To Resources are Equipment, Material and Personnel in ISA95, but they can be expanded to other types. 20 rce Flow Resource Money Material Person Equipment IS IT Asset Information Energy 3_30_ISA8895_Function_PhysicalProcessManagement Process Segment ISA95 + EPE ISA88 Fabrication support Traitement De surface Bobinage Segments Personnel Equipment Material Process Parameters (e.g. Grammage) Cellule Process Procédure Procédure d'Unité Opération material Unité Module Équipement Module de Contrôle Phase Personnel 3_30_ISA8895_Function_PhysicalProcessManagement Equipment ISA88 defines Equipment and Recipe Procedural Elements that are related to Equipment entities. EPE and RPE are inherited by the segment through the Equipment entities it encompasses. They constitute the behavioural aspects of the segment 21 Operation segment Location 1...1 0...n Operation Segment 0...n Corresponds to 0...n Process Element 0...n 0...n 0..n 0..n 0..n Is build on 0...n Is based on 0..n IT Asset 0..n 0..n Is fulfilled by EPE 0..n 0..n Service Activates 0...n 0...n RPE SOP MRTC 0...n Data Parameter Data Parameter 3_30_ISA8895_Function_PhysicalProcessManagement 22 Correspond to 0...1 Taken From Personnel Consumed Equipment Produced Resource Material Tested IT Asset Sent To ... ... From Equipment Is implemented by 0...n 0..n KPI Data Parameter Agenda Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise 3_30_ISA8895_Function_PhysicalProcessManagement 23 Exercise 1 Identify a set of segments classes of a facility of your choice Associate Personnel Classes, Equipment Classes and Material Classes to these segments Create instances of these segments for a given facility 3_30_ISA8895_Function_PhysicalProcessManagement 24