.
District 12 & Qatar Section
Interoperability: ISA-95 part 2 / B2MML use cases
Jean Vieille
Control Chain Group
Standards Certification Education & Training Publishing Conferences & Exhibits
Past ISA D12 Vice President, France section President ISA-88/95/106 committee member
ISA Automation Conference Doha (Qatar) - 9 & 10 December 2012
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
2
ISA-95 pradigm : Scope / goal
This standard describes the interface content between manufacturing operations and control functions and other enterprise functions. .... The goals are to increase uniformity and consistency of interface terminology and reduce the risk, cost, and errors associated with implementing these interfaces. The standard can be used to reduce the effort associated with implementing new product offerings. The goal is to have enterprise systems and control systems that inter-operate and easily integrate.
3
ISA95 snapshot
· B2M: Collaboration Business / Execution
Communication between execution systems (MES/MOM, DCS, MMS, LIMS, WES, SCADA,...) and business systems (ERP, SCM) Master data management
· MES/MOM : Functional definition · Data and Activity models
Description of resources, capability, products, work order requests and reports Definition of operation management activities (MES)
· Applications:
User requirements and functional specification of MES and B2M interfaces Native B2M connectors - MES/ERP (B2MML) Possible basis for developing MES applications and software...
4
What is ISA-95?
· · · · US & International standard "Enterprise - Control System Integration" The ISA95 committee develops the ISA-95 standards The ISO/IEC JWG5 develops the international standard MSEA/WBF develops the XML implementation of the data models
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: Objects and attributes for manufacturing operations management integration Part 5: Business to Manufacturing Transactions Business to Manufacturing Markup Language
US standard ANSI/ISA-95.00.01: 2010 ANSI/ISA-95.00.02: 2010 ANSI/ISA-95.00.03: 2005 ANSI/ISA 95.00.04 2012 ASNI/ISA-95.00.05: 2007 + B2MML V06
5
Business-Operation systems Interface according to ISA95 part 2
Level 4 BusinessBusiness Planning & Logistics
Systems (ERP, LIMS, WMS, MMS, SCM...)
Level 3 Manufacturing Operations & Control
Plant Production Scheduling, Operational Management, etc
Manufacturing Systems Levels MES, ERP, LIMS, WES, MMS, SCE 2,1,0 DCS, PLCs, SCADA... Batch Continuous Discrete
Control Control Control
6
Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...
ISA-95 part 2 Models and terminology for manufacturing information
Business planning & logistics information
Plant production scheduling, operational management, etc (Operation) definition information
(What must be defined to make The job)
(Operation) capability information
(What resources are available)
(Operation) schedule information
(What actual job will be executed)
(Operation) performance information
(What actual job was achieved)
Manufacturing operations management information
Production operations, maintenance operations, quality operations, etc
Operations = Production, Maintenance, Quality, Inventory
7
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
8
Context and challenge
· Central ERP system + hundreds of factories worldwide · 3 selected control/MES vendors · Difficult decision taken between
Let vendors taking care of integration Adopt a company wide interoperability language : vendor neutral / company responsible ISA-95 interface
· Designed in Europe, developed in India, implemented and used everywhere
9
Interface scope : 20 messages (phase 1)
ERP->MES Production transaction · Production Orders · PO status change MES-> ERP · PO reports : material produced, consummed, down times · PO status change · TO reports and cancellation · "Spontaneous" transfer · Raw material reception · Material status change · Inventory query
Logistics transactions
· Transfer Orders in and inter plants
Inventory transactions
· Material status change · Inventory response
10
Work methodology
· Messages identification and content provided by ERP functional consultants
Factories IT, MES vendors / integrators were never invited! Opportunistic design, no high level guidance
· Mapping of message through workshops involving
ERP consultants, ISA-95 expert
· Extension and adaptation of ISA-95, B2MML
Company specific B2MML and ISA-95 extensions to overcome their limitations at this time (2004) a major input for the next releases
ISA-95: Handling of inventory (and other) operations types B2MML: Custom extensions
11
Specification structure
· Very simple:
we don't care of systems but ERP Everyone speaks SAP in the design team... All other parties will just need to know ISA-95 (MES integrators)
+ISA-95 models (ex : Operations Schedule)
+Message (ex : Process Production orders)
+Message rows
ISA-95 concept (ex : SegmentRequirement.ID) SAP field (ex : Y_MES_H PPPI_CONTROL_RECIPE )
12
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
13
Enterprise bus ISA-95 messages
MES connectors
Outcome
· Outcome
Design of ERP/MES through ISA-95 like enterprise language
only needs to be considered from ERP can ignore MES No need for ERP / MES meetings
Interface deployed worldwide « Perfect delivery »
the initial spec/schemas are still in use - no update after 8 years
Subsequent extension for Quality
· ISA-95 support : 40 days / 1 year
Detailed message definition, Functional specification writing Many meetings...
14
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
15
Context and challenge
· Central ERP system + 3 factories in Europe · ESB Messaging framework available but deemed too expensive / complex => abandoned · Objective :
Enterprise controlled interfaces Integration implemented by MES vendor using native systems interfaces
16
Interface scope : 14 messages
ERP->MES Production transaction Inventory transactions Master data transactions · Production Orders · PO change · Sync material lots · Sync material definitions · Sync Equipment definitions MES-> ERP · PO reports : material produced, consumed,
17
Work methodology
· Messages identification and content provided by company's business consultants · Build a taxonomy of the enterprise language · Provide a mapping
based on business terms Providing translation in ERP and MES terminology
· Only 3 meetings to gather requirements and wrap up the whole detailed mapping specification
18
Specification structure
· More elaborated
The goal is to be understood by Business, ERP and MES people Still simple: only 2 systems involved
· Dictionary
Business terms with definitions
+ISA-95 models (ex : Operations Schedule)
+Messages
+ message rows
ISA-95 concept (ex : SegmentRequirement.ID) Business data SAP data (ex : Y_MES_H PPPI_CONTROL_RECIPE ) MES data
(ex : Process Production orders)
19
Outcome
· Outcome
A handy spec detailing all messages in 3 languages : ERP, MES and Business
understandable by all stakeholders
Only a specification
No messaging involved, Direct peer to peer connexion between MES and ERP under vendor's responsibility
· ISA-95 support: 15 days / 1 month
Detailed message definition
20
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
21
Context and challenge
· A complex interface project involving 7 different systems
The most complex among these 3 use cases
· Strictly limited budget for external support
2 days workshop planned for knowledge transfer Design to realized internally
22
Interface scope : 20 messages
ERP/MDM/LIMS/SCADA ->MES Production transaction Logistics transactions Quality transactions Inventory transactions Master data transactions ·Quality report · Material reception · Material quality · Sync material definitions · PO reports · Temperature reports MES-> ERP/LIMS/SCADA · deviation reports and ack · Production orders · Material movements Quality order · Weight control order
23
Work methodology
Only 2 days budget : · 1st day :
Teach ISA-95+B2MML: High speed knowledge transfer Team's brain overload Manager's desperation : "Find another way by tomorrow"
· 2nd day
All 20 messages identified and drafted Definition of an XML enforced company language +ISA-95 spirit
Using an ISA-95 (really simple) meta-model
· 3rd day (over-budget)
Review of the internal team work
24
Specification structure
· Most sophisticated
Multiple systems involved * Definition of a company specific language, from the actual interoperability needs No ISA-95 involved, but its rational
+Transaction class (ex: material master)
+ISA-95-like* models (ex : Material)
+Transaction Messages
+ message rows
ISA-95 concept (ex : SegmentRequirement.ID) Business data Origin system data (ex : Y_MES_H PPPI_CONTROL_RECIPE ) Destination system
(ex : Create Material)
25
Outcome
· Outcome
Full autonomy achieved in 3 days Smart design Low cost
· ISA-95 support : 3 days / 1week
Get the team thinking the ISA-95 way
26
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
27
Different way of leveraging the ISA-95 standard · Can be used for
Requirement specification (ISA-95) Actual messages generation (BMML)
· Can represent
The canonical enterprise language A meta language for a company specific language
· Is independent of the middleware technology
Peer-to-peer proprietary synchronous connexions XML based asychronous messaging middleware Other : text file transfer...
· Investment varies in large extend
Almost independent of the scope and complexity
28
J. Vieille's Professional biography
37 years of experience in Information support to industrial systems · Control and management of industrial operations
Modular/Flexible Automation ISA-88 Operations Management (MES/MOM) ISA-95 IT Systems Interoperability B2MML
· ·
Industrial IT governance and Organization
Support to Business Operations and transformation
Software solutions
Assessment and selection Functional architecture design roadmap, technology acquisitions
·
Information physics and systems theory ISA
Past D12 Vice President and France section President ISA-88 and ISA-95 member
29
Thank You
j.vieille@controlchaingroup.com www.syntropicfactory.com www.controlchaingroup.net
Download this presentation (latest update)
www.syntropicfactory.com/node/3799
30
Interoperability: ISA-95 part 2 / B2MML use cases
Jean Vieille
Control Chain Group
Standards Certification Education & Training Publishing Conferences & Exhibits
Past ISA D12 Vice President, France section President ISA-88/95/106 committee member
ISA Automation Conference Doha (Qatar) - 9 & 10 December 2012
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
2
ISA-95 pradigm : Scope / goal
This standard describes the interface content between manufacturing operations and control functions and other enterprise functions. .... The goals are to increase uniformity and consistency of interface terminology and reduce the risk, cost, and errors associated with implementing these interfaces. The standard can be used to reduce the effort associated with implementing new product offerings. The goal is to have enterprise systems and control systems that inter-operate and easily integrate.
3
ISA95 snapshot
· B2M: Collaboration Business / Execution
Communication between execution systems (MES/MOM, DCS, MMS, LIMS, WES, SCADA,...) and business systems (ERP, SCM) Master data management
· MES/MOM : Functional definition · Data and Activity models
Description of resources, capability, products, work order requests and reports Definition of operation management activities (MES)
· Applications:
User requirements and functional specification of MES and B2M interfaces Native B2M connectors - MES/ERP (B2MML) Possible basis for developing MES applications and software...
4
What is ISA-95?
· · · · US & International standard "Enterprise - Control System Integration" The ISA95 committee develops the ISA-95 standards The ISO/IEC JWG5 develops the international standard MSEA/WBF develops the XML implementation of the data models
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: Objects and attributes for manufacturing operations management integration Part 5: Business to Manufacturing Transactions Business to Manufacturing Markup Language
US standard ANSI/ISA-95.00.01: 2010 ANSI/ISA-95.00.02: 2010 ANSI/ISA-95.00.03: 2005 ANSI/ISA 95.00.04 2012 ASNI/ISA-95.00.05: 2007 + B2MML V06
5
Business-Operation systems Interface according to ISA95 part 2
Level 4 BusinessBusiness Planning & Logistics
Systems (ERP, LIMS, WMS, MMS, SCM...)
Level 3 Manufacturing Operations & Control
Plant Production Scheduling, Operational Management, etc
Manufacturing Systems Levels MES, ERP, LIMS, WES, MMS, SCE 2,1,0 DCS, PLCs, SCADA... Batch Continuous Discrete
Control Control Control
6
Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...
ISA-95 part 2 Models and terminology for manufacturing information
Business planning & logistics information
Plant production scheduling, operational management, etc (Operation) definition information
(What must be defined to make The job)
(Operation) capability information
(What resources are available)
(Operation) schedule information
(What actual job will be executed)
(Operation) performance information
(What actual job was achieved)
Manufacturing operations management information
Production operations, maintenance operations, quality operations, etc
Operations = Production, Maintenance, Quality, Inventory
7
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
8
Context and challenge
· Central ERP system + hundreds of factories worldwide · 3 selected control/MES vendors · Difficult decision taken between
Let vendors taking care of integration Adopt a company wide interoperability language : vendor neutral / company responsible ISA-95 interface
· Designed in Europe, developed in India, implemented and used everywhere
9
Interface scope : 20 messages (phase 1)
ERP->MES Production transaction · Production Orders · PO status change MES-> ERP · PO reports : material produced, consummed, down times · PO status change · TO reports and cancellation · "Spontaneous" transfer · Raw material reception · Material status change · Inventory query
Logistics transactions
· Transfer Orders in and inter plants
Inventory transactions
· Material status change · Inventory response
10
Work methodology
· Messages identification and content provided by ERP functional consultants
Factories IT, MES vendors / integrators were never invited! Opportunistic design, no high level guidance
· Mapping of message through workshops involving
ERP consultants, ISA-95 expert
· Extension and adaptation of ISA-95, B2MML
Company specific B2MML and ISA-95 extensions to overcome their limitations at this time (2004) a major input for the next releases
ISA-95: Handling of inventory (and other) operations types B2MML: Custom extensions
11
Specification structure
· Very simple:
we don't care of systems but ERP Everyone speaks SAP in the design team... All other parties will just need to know ISA-95 (MES integrators)
+ISA-95 models (ex : Operations Schedule)
+Message (ex : Process Production orders)
+Message rows
ISA-95 concept (ex : SegmentRequirement.ID) SAP field (ex : Y_MES_H PPPI_CONTROL_RECIPE )
12
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
13
Enterprise bus ISA-95 messages
MES connectors
Outcome
· Outcome
Design of ERP/MES through ISA-95 like enterprise language
only needs to be considered from ERP can ignore MES No need for ERP / MES meetings
Interface deployed worldwide « Perfect delivery »
the initial spec/schemas are still in use - no update after 8 years
Subsequent extension for Quality
· ISA-95 support : 40 days / 1 year
Detailed message definition, Functional specification writing Many meetings...
14
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
15
Context and challenge
· Central ERP system + 3 factories in Europe · ESB Messaging framework available but deemed too expensive / complex => abandoned · Objective :
Enterprise controlled interfaces Integration implemented by MES vendor using native systems interfaces
16
Interface scope : 14 messages
ERP->MES Production transaction Inventory transactions Master data transactions · Production Orders · PO change · Sync material lots · Sync material definitions · Sync Equipment definitions MES-> ERP · PO reports : material produced, consumed,
17
Work methodology
· Messages identification and content provided by company's business consultants · Build a taxonomy of the enterprise language · Provide a mapping
based on business terms Providing translation in ERP and MES terminology
· Only 3 meetings to gather requirements and wrap up the whole detailed mapping specification
18
Specification structure
· More elaborated
The goal is to be understood by Business, ERP and MES people Still simple: only 2 systems involved
· Dictionary
Business terms with definitions
+ISA-95 models (ex : Operations Schedule)
+Messages
+ message rows
ISA-95 concept (ex : SegmentRequirement.ID) Business data SAP data (ex : Y_MES_H PPPI_CONTROL_RECIPE ) MES data
(ex : Process Production orders)
19
Outcome
· Outcome
A handy spec detailing all messages in 3 languages : ERP, MES and Business
understandable by all stakeholders
Only a specification
No messaging involved, Direct peer to peer connexion between MES and ERP under vendor's responsibility
· ISA-95 support: 15 days / 1 month
Detailed message definition
20
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
21
Context and challenge
· A complex interface project involving 7 different systems
The most complex among these 3 use cases
· Strictly limited budget for external support
2 days workshop planned for knowledge transfer Design to realized internally
22
Interface scope : 20 messages
ERP/MDM/LIMS/SCADA ->MES Production transaction Logistics transactions Quality transactions Inventory transactions Master data transactions ·Quality report · Material reception · Material quality · Sync material definitions · PO reports · Temperature reports MES-> ERP/LIMS/SCADA · deviation reports and ack · Production orders · Material movements Quality order · Weight control order
23
Work methodology
Only 2 days budget : · 1st day :
Teach ISA-95+B2MML: High speed knowledge transfer Team's brain overload Manager's desperation : "Find another way by tomorrow"
· 2nd day
All 20 messages identified and drafted Definition of an XML enforced company language +ISA-95 spirit
Using an ISA-95 (really simple) meta-model
· 3rd day (over-budget)
Review of the internal team work
24
Specification structure
· Most sophisticated
Multiple systems involved * Definition of a company specific language, from the actual interoperability needs No ISA-95 involved, but its rational
+Transaction class (ex: material master)
+ISA-95-like* models (ex : Material)
+Transaction Messages
+ message rows
ISA-95 concept (ex : SegmentRequirement.ID) Business data Origin system data (ex : Y_MES_H PPPI_CONTROL_RECIPE ) Destination system
(ex : Create Material)
25
Outcome
· Outcome
Full autonomy achieved in 3 days Smart design Low cost
· ISA-95 support : 3 days / 1week
Get the team thinking the ISA-95 way
26
Agenda
· · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion
27
Different way of leveraging the ISA-95 standard · Can be used for
Requirement specification (ISA-95) Actual messages generation (BMML)
· Can represent
The canonical enterprise language A meta language for a company specific language
· Is independent of the middleware technology
Peer-to-peer proprietary synchronous connexions XML based asychronous messaging middleware Other : text file transfer...
· Investment varies in large extend
Almost independent of the scope and complexity
28
J. Vieille's Professional biography
37 years of experience in Information support to industrial systems · Control and management of industrial operations
Modular/Flexible Automation ISA-88 Operations Management (MES/MOM) ISA-95 IT Systems Interoperability B2MML
· ·
Industrial IT governance and Organization
Support to Business Operations and transformation
Software solutions
Assessment and selection Functional architecture design roadmap, technology acquisitions
·
Information physics and systems theory ISA
Past D12 Vice President and France section President ISA-88 and ISA-95 member
29
Thank You
j.vieille@controlchaingroup.com www.syntropicfactory.com www.controlchaingroup.net
Download this presentation (latest update)
www.syntropicfactory.com/node/3799
30
Johann Sebastian Bach. the music closest to silence, closest, in spite of its being so highly organized, to pure, one-hundred-degree proof Spirit" (Aldous Huxley, Island)